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SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS

3121619

5-13

Assembly Instructions for O-Ring Face Seal (ORFS) 
Fittings

1.

Ensure proper O-ring is installed. If O-ring is missing
install per O-ring Installation (Replacement).

2.

Ensure surface is smooth, free of rust, weld and brazing
splatter, splits, dirt, foreign matter, or burrs. If necessary
replace fitting or adapter.

CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID ADDING OIL TO
THE THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD
CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE.

3.

Pre-lubricate the O-ring with Hydraulic Oil. 

4.

Place the tube assembly against the fitting body so that
the flat face comes in contact with the O-ring. Hand
thread the nut onto the fitting body.

5.

Torque nut to value listed in Table 5-7, O-ring Face Seal
(ORFS) - Steel or Table 5-8, O-ring Face Seal (ORFS) - Alu-
minum/Brass while using the Double Wrench Method.
Refer to FFWR and TFFT Methods for procedure require-
ments if using the FFWR method.   

NOTE:

Torque values provided in Table 5-7, O-ring Face Seal
(ORFS) - Steel and Table 5-8, O-ring Face Seal (ORFS) - Alu-
minum/Brass are segregated based on the material config-
uration of the connection.

ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
COMPONENTS’ indicate either the following material configu-
rations:

• STEEL fittings with ALUMINUM or BRASS mating compo-

nents

• ALUMINUM or BRASS fittings with STEEL mating compo-

nents

• ALUMINUM or BRASS fittings with ALUMINUM or 

BRASS mating components

Table 5-7. 

O-ring Face Seal (ORFS)

 - Steel

TYPE/FITTING IDENTIFICATION

Torque

Flats from Wrench 

Resistance 
(F.F.W.R)**

MA

TER

IAL

Dash Size

Thread Size

ØA*

ØB*

[Ft-Lb]

[N-m]

Tube 

Nuts

Swivel & 

Hose 

Ends

(UNF)

(in)

(mm)

(in)

(mm)

Min

Nom

Max

Min

Nom

Max

STEEL FIT

TINGS W

ITH 

 

ST

EEL MA

TI

NG C

O

MPONENT

S;

 

UN-L

UBRIC

ATED THREADS

4

9/16-18

0.51

13.00

0.56

14.20

18

19

20

25

26

27

1/4 to 1/2

1/2 to 3/4

6

11/16-16

0.63

15.90

0.69

17.50

30

32

33

40

43

45

1/4 to 1/2

1/2 to 3/4

8

13/16-16

0.75

19.10

0.81

20.60

40

42

44

55

57

60

1/4 to 1/2

1/2 to 3/4

10

1-14

0.94

23.80

1.00

25.40

60

63

66

81

85

89

1/4 to 1/2

1/2 to 3/4

12

1 3/16-12

1.11

28.20

1.19

30.10

85

90

94

115

122

127

1/4 to 1/2

1/2 to 3/4

16

1 7/16-12

1.34

34.15

1.44

36.50

110

116

121

149

157

164

1/4 to 1/2

1/2 to 3/4

20

1 11/16-12

1.59

40.50

1.69

42.90

150

158

165

203

214

224

1/4 to 1/2

1/2 to 3/4

24

2-12

1.92

48.80

2.00

50.80

230

242

253

312

328

343

1/4 to 1/2

1/2 to 3/4

32

2 1/2-12

2.43

61.67

2.50

63.50

375

394

413

508

534

560

1/4 to 1/2

1/2 to 3/4

* ØA and ØB thread dimensions for reference only.

** See FFWR and TFFT Methodsfor FFWR procedure requirements.

Содержание 1850SJ

Страница 1: ...Service and Maintenance Manual Model 1850SJ 3121619 June 29 2018 Rev J AS NZS...

Страница 2: ......

Страница 3: ...ic systems oper ate at extremely high potentially dangerous pressures Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system Do not use...

Страница 4: ...ue A June 18 2014 Revised B September 25 2014 Revised C May 15 2015 Revised D November 5 2015 Revised E January 27 2016 Revised F June 8 2016 Revised G November 8 2016 Revised H May 23 2017 Revised I...

Страница 5: ...2 2 General 2 2 Safety and Workmanship 2 2 Cleanliness 2 2 Components Removal and Installation 2 2 Component Disassembly and Reassembly 2 3 Pressure Fit Parts 2 3 Bearings 2 3 Gaskets 2 3 Bolt Usage a...

Страница 6: ...3 15 Swing Control System 3 47 3 16 Chassis Tilt Indicator System 3 47 3 17 Auxiliary Power System 3 47 3 18 Water in Fuel Sensing System Optional 3 48 3 19 Deutz Turbocharger Operation 3 48 Operating...

Страница 7: ...nal Replacement Criteria 4 57 4 12 Wire Rope Tensioning Adjustment 4 58 Boom Preparation for Section Repositioning 4 58 Wire Rope Tensioning Procedure 4 64 Confirm Proper Boom Deployment Function 4 66...

Страница 8: ...placement 5 49 5 3 Hydraulic Cylinders 5 59 Axle Extend Cylinder 5 59 Jib Level Slave Cylinder 5 64 Platform Level Cylinder 5 70 Boom Lift Cylinder 5 76 Jib Lift Cylinder 5 82 Jib Lock Cylinder 5 88 S...

Страница 9: ...Level Angle Sensor 1 6 47 Sensor 7 Jib Lock Pin Proximity Sensor 1 6 47 Sensor 8 Jib Stow Angle Sensor 1 6 49 Sensor 9 Jib Lift Angle Sensor 1 6 49 Sensor 10 Dual Capacity Jib Transport Length Switch...

Страница 10: ...ement 7 1 Resistance Measurement 7 2 Continuity Measurement 7 2 Current Measurement 7 3 7 3 Applying Silicone Dielectric Compound to Electrical Connections 7 3 Installation of Dielectric Grease 7 4 De...

Страница 11: ...t Sheet 2 of 2 3 10 3 9 Turntable Hydraulic System 3 11 3 10 Drive Assembly 3 12 3 11 Drive Hub 3 13 3 12 Disengaging Drive Hubs 3 21 3 13 Gear Hub Oil Fill and Drain 3 21 3 14 Drive Motor 3 22 3 15 D...

Страница 12: ...Sheet 7 of8 3 58 3 53 Diesel Exhaust Fluid DEF System Sheet 6 of 7 3 59 3 54 Engine Electrical Circuit 3 60 3 55 Mixing Petroleum With Summer Diesel Fuel 3 61 4 1 Boom Hydraulic System 4 7 4 2 Boom As...

Страница 13: ...ertrack Shimming Instructions 4 72 4 45 Powertrack Locations for Threadlocker Application and Torque Sheet 1 of 4 4 73 4 46 Powertrack Locations for Threadlocker Application and Torque Sheet 2 of 4 4...

Страница 14: ...ing Installation 5 63 5 33 Seating the Tapered Bearing 5 63 5 34 Rod Assembly Installation 5 63 5 35 Cylinder Barrel Support 5 64 5 36 Capscrew Removal 5 64 5 37 Cylinder Rod Support 5 64 5 38 Jib Lev...

Страница 15: ...ensor Removal 5 82 5 78 Capscrew Removal 5 82 5 79 Jib Lift Cylinder Assembly 5 83 5 80 Cylinder Rod Support 5 84 5 81 Tapered Bushing Removal 5 84 5 82 Piston Disassembly 5 84 5 83 Cylinder Head Disa...

Страница 16: ...5 124 Main Valve Identification Sheet 1 of 2 5 110 5 125 Main Valve Identification Sheet 2 of 2 5 111 5 126 Main Valve Torque Values Sheet 1 of 2 5 112 5 127 Main Valve Torque Values Sheet 2 of 2 5 1...

Страница 17: ...are Version 7 X Sheet 4 of 4 6 35 6 18 Ground Control Module Sheet 1 of 3 6 36 6 19 Ground Control Module Sheet 2 of 3 6 37 6 20 Ground Control Module Sheet 3 of 3 6 38 6 21 Chassis Control Module 6 3...

Страница 18: ...3 7 28 Jib Valve Wiring Harness Sheet 1 of 3 7 24 7 29 Jib Valve Wiring Harness Sheet 2 of 3 7 25 7 30 Jib Valve Wiring Harness Sheet 3 of 3 7 26 7 31 BLAM Module Wiring Harness Sheet 1 of 2 7 27 7 32...

Страница 19: ...T4F Engine Harness Sheet 4 of 14 7 69 7 74 T4F Engine Harness Sheet 5 of 14 7 70 7 75 T4F Engine Harness Sheet 6 of 14 7 71 7 76 T4F Engine Harness Sheet 7 of 14 7 72 7 77 T4F Engine Harness Sheet 8 o...

Страница 20: ...et 7 of 21 7 103 7 108 Electrical Schematic Sheet 8 of 21 7 104 7 109 Electrical Schematic Sheet 9 of 21 7 105 7 110 Electrical Schematic Sheet 10 of 21 7 106 7 111 Electrical Schematic Sheet 11 of 21...

Страница 21: ...3121619 xvii LIST OF FIGURES FIGURE NO TITLE PAGE NO Thispageleftblankintentionally...

Страница 22: ...e SAE Steel 5 12 5 6 45 Flare SAE Aluminum Brass 5 12 5 7 O ring Face Seal ORFS Steel 5 13 5 8 O ring Face Seal ORFS Aluminum Brass 5 14 5 9 DIN 24 Cone MBTL MBTS 5 16 5 10 Bulkhead Fittings BH INCH 5...

Страница 23: ...er Size and Torque Chart 5 148 5 42 Plug Size and Torque Chart 5 148 5 43 Troubleshooting 5 169 6 1 Analyzer Abbreviations 6 8 6 2 Machine Configuration Programming Information 6 10 6 3 Machine Config...

Страница 24: ...xx 3121619 LIST OF TABLES TABLE NO TITLE PAGE NO Thispageleftblankintentionally...

Страница 25: ...ht stowed 10ft 0 5in 3 06m MachineLength stowed 47ft 9 5in 14 57m PlatformHeight 500lb 230kg capacity 185ft 7in 56 56m PlatformHeight 1000lb 450kg capacity 165ft 2in 50 34m HorizontalReachfromcenterli...

Страница 26: ...procedures Table 1 6 Critical Stability Weights Components LBS KG Tire Wheel 1025 465 DriveHub Motor 337 153 SwingDrive 223 101 2 EngineAssembly 822 373 CompleteBoom includingjib platform 23 600 1070...

Страница 27: ...theticBiodegradable ISOViscosityGrade 46 SpecificGravity 910 PourPoint 44 F 42 C FlashPoint 500 F 260 C OperatingTemp 0to180 F 17to162 C Weight 7 64lb pergal 0 9kgperliter Viscosity at40 C 45cSt at100...

Страница 28: ...SECTION 1 SPECIFICATIONS 1 4 3121619 11 10 13 15 12 18 14 6 3 3 3 3 1 7 9 2 5 8 16 17 4 Figure 1 1 Maintenance and Lubrication Diagram...

Страница 29: ...bearing is completely lubricated 2 Swing Gearbox Lube Point s Fill Plug Capacity 3 qt 2 8 L Lube GL 5 Interval Check level every 150 hrs Change every 1200 hours of operation Fill to cover ring gear 3...

Страница 30: ...every 6 months or 300 hrs thereafter Comments Remove wing nut and cover to replace Under certain conditions it may be necessary to replace on a more frequent basis 6 Hydraulic Charge Filter Lube Poin...

Страница 31: ...y 2 years or 1200 hours of operation 9 Main Valve Filter Lube Point s Replaceable Element Interval Change after first 50 hours and every 6 months or 300 hours thereafter 10 Oil Change w Filter Deutz L...

Страница 32: ...ilter Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation or as indicated by the condition indicator Comments Check dust valve for dirt daily 14 Boom Lube Point s Apply...

Страница 33: ...oint Fill Cap Lube DEF Capacity 5 7 gal 21 5 L 17 DEF Supply Module Filter If Equipped Interval 500 hours or 2 years whichever comes first 18 Optional Fuel Filter Water Separator Lube Point s Replacea...

Страница 34: ...SECTION 1 SPECIFICATIONS 1 10 3121619 Figure 1 2 Torque Chart Sheet 1 of 5 SAE Fasteners Torq ue To rqu e Torq ue To rqu e Torq ue Torq ue...

Страница 35: ...SECTION 1 SPECIFICATIONS 3121619 1 11 Figure 1 3 Torque Chart Sheet 2 of 5 SAE Fasteners Torq ue Tor que Torq ue Torqu e To rqu e...

Страница 36: ...SECTION 1 SPECIFICATIONS 1 12 3121619 Figure 1 4 Torque Chart Sheet 3 of 5 SAE Fasteners Cl amp L oa d To rque To rqu e Torq ue Torqu e Tor que Torq ue...

Страница 37: ...SECTION 1 SPECIFICATIONS 3121619 1 13 Figure 1 5 Torque Chart Sheet 4 of 5 METRIC Fasteners To rqu e To rqu e Torq u e To rq ue To rqu e To rq ue...

Страница 38: ...SECTION 1 SPECIFICATIONS 1 14 3121619 Figure 1 6 Torque Chart Sheet 5 of 5 METRIC Fasteners Torq ue To rqu e Tor qu e To rqu e To rqu e To rq ue...

Страница 39: ...ery The Frequent Inspection shall be accomplished for each machine in service for 3 months or 150 hours whichever comes first out of service for a period of more than 3 months or when purchased used T...

Страница 40: ...containers until they are ready to be used Components Removal and Installation 1 Use adjustable lifting devices whenever possible if mechanical assistance is required All slings chains cables etc sho...

Страница 41: ...ssary to hand fabricate a gasket use gasket material or stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage Bolt Usag...

Страница 42: ...ned flushed and refilled with clean oil 4 It is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities Good grade mi...

Страница 43: ...temper ature Cylinder Leakage Test Cylinder oil must be at stabilized ambient temperature before beginning this test Measure drift at cylinder rod with a calibrated dial indicator In an area free of o...

Страница 44: ...wound bearing are a dry joint and should not be lubricated unless otherwise instructed i e sheave pins c Pins should be inspected to ensure it is free of burrs nicks and scratches which would damage...

Страница 45: ...1 2 Extend RetractChainorCableSystems 1 2 3 1 2 3 PlatformAssembly Platform 1 2 Railing 1 1 2 Gate 1 5 1 5 Floor 1 1 2 Rotator 5 9 15 LanyardAnchoragePoint 1 2 10 1 2 10 TurntableAssembly SwingBearin...

Страница 46: ...ndBreather 1 2 5 1 5 Hydraulic ElectricSystem HydraulicPumps 1 2 9 HydraulicCylinders 1 2 7 9 1 2 9 CylinderAttachmentPinsandPinRetainers 1 2 9 1 2 HydraulicHoses Lines andFittings 1 2 9 12 1 2 9 12 H...

Страница 47: ...roperandsecureinstallation 2 Visualinspectionfordamage cracks distortionorexcessivewear 3 Checkforproperadjustment 4 Checkforcrackedorbrokenwelds 5 OperatesProperly 6 Returnstoneutralor off positionwh...

Страница 48: ...SECTION 2 GENERAL 2 10 3121619 Figure 2 1 Engine Operating Temperature Specifications Deutz 1001159163 A...

Страница 49: ...ity at 40 C cSt Typical Viscosity Index Mineral Oils Vegetable Oils Synthetic Synthetic Polyol Esters Readily Biodegradable Virtually Non toxic Fire Resistant Mobilfluid424 55 145 X MobilDTE10Excel32...

Страница 50: ...SECTION 2 GENERAL 2 12 3121619 NOTES...

Страница 51: ...width center piece location larger or smaller diameter etc without written factory recommendations may result in an unsafe condition regarding stability Wheel Installation It is extremely important to...

Страница 52: ...the transport position The steering angle will be automatically limited to 20 degrees anytime the axles are not fully extended If the wheel angle is more than 20 degrees when the axle retract command...

Страница 53: ...Axle Extension System for interaction with the axle extension system If a wheel cannot achieve its com manded angle within a specified time it is considered jammed When a wheel is considered jammed d...

Страница 54: ...e tighter the turn the slower the allowable drive speed As crab steer does not steer on a radius full drive speed is maintained regardless of steer angle 3 6 TRACTION CONTROL SYSTEM The traction contr...

Страница 55: ...SECTION 3 CHASSIS TURNTABLE 3121619 3 5 This page left blank intentionally...

Страница 56: ...SECTION 3 CHASSIS TURNTABLE 3 6 3121619 Figure 3 4 Axle Hose Routing Sheet 1 of 2...

Страница 57: ...SECTION 3 CHASSIS TURNTABLE 3121619 3 7 Figure 3 5 Axle Hose Routing Sheet 2 of 2...

Страница 58: ...SECTION 3 CHASSIS TURNTABLE 3 8 3121619 Figure 3 6 Steering Axle Hydraulic Circuit...

Страница 59: ...WIVEL PORT 3 A1 B1 BR B2 A2 TS A6 A4 B4 RIGHT R IGH T RE AR H U B DR IVE M OTOR A B X X A B X X REAR LEFT LEFT R EAR H UB D R IV E MOTOR A B X X FRONT LEFT FR ONT H UB D R IV E MOTOR A B X X FR ON T V...

Страница 60: ...R L EFT RIGHT TO SWIVEL PORT 7 X X X X X X X X LEFT FRONT HUB DRIVE MOTOR X RIGHT REAR HUB DRIVE MOTOR X X1 L1 RIGHT FRONT HUB DRIVE MOTOR X L1 BR X1 LEFT REAR HUB DRIVE MOTOR X CASE DRAIN MANIFOLD T...

Страница 61: ...SECTION 3 CHASSIS TURNTABLE 3121619 3 11 Figure 3 9 Turntable Hydraulic System...

Страница 62: ...SECTION 3 CHASSIS TURNTABLE 3 12 3121619 3 7 DRIVE ASSEMBLY Figure 3 10 Drive Assembly 1 2 3 4 5 6 7 1 DriveHub 2 O Ring 3 Drivemotor 4 Washer 5 Bolt 6 Washer 7 Bolt...

Страница 63: ...lange 26 O Ring 27 RingNut 28 SetScrew 29 Bearing 30 HubSupport 31 O Ring 32 Bearing 33 Seal 34 Coupling 35 Spring 36 RetainingRing 37 Bearing 38 Axle 39 Plug 40 Plug 41 PlasticPlug 42 InputShaft 43 I...

Страница 64: ...screws 56 motor flange 55 and O Ring 54 Do not damage O Ring 3 Remove two screws 2 cover 3 and pin 4 4 Remove Ring 1 Cover 6 O Ring 7 Spacer 8 and O Ring 10 Do not damage O Rings Check and remove Gask...

Страница 65: ...tary Ring 18 and O Ring 26 Do not damage O Ring 7 Remove Coupling 34 and Spring 35 8 Remove three snap rings 22 and planetary gears 24 from spindles on Flange 25 9 Remove two Set Screws 28 from Ring N...

Страница 66: ...le 38 12 Remove Snap Ring 53 Spacer 52 Seal 48 O Ring 49 and Brake Piston 50 from Axle 38 Remove five Brake Springs 51 from Brake Piston 50 Use com pressed air to remove Brake Piston from Axle 13 Remo...

Страница 67: ...nd Bearing Secure with Split Ring 36 3 Install Seal 46 O Ring 47 Seal 48 and O Ring 49 in Axle 38 Starting with Brake Disk 43 alternate with Iron Disk 44 until a total of eight Brake Disks and nine Ir...

Страница 68: ...with convex part facing bearing 7 Install Ring Nut 27 on Flange 25 Prevent Flange from turning and torque Ring Nut to 295 ft lb 400 Nm Tighten and back off two times to completely seat bear ings Tight...

Страница 69: ...11 Install Gear Reduction Assembly 16 Gear Reduction Assembly 13 and Pinion 11 in Planetary Housing Lubricate all bearings 12 Install O Ring 7 and O Ring 10 in Cover 6 Liberally coat Spacer 8 with gr...

Страница 70: ...completed Drive Hub assembly rotates freely 15 Install Pin 4 and Cover 3 Secure with two Screws 2 Torque to 7 ft lb 10 Nm FAILURE TO PROPERLY FILL DRIVE HUB WITH OIL BEFORE OPERATION WILL RESULT IN E...

Страница 71: ...OIL SERVICE Check Oil Level 1 Position hub as shown in Figure 3 13 2 Remove Level Plug 3 and check oil is level with plug opening Add oil as needed 3 Reinstall plug Change Gear Hub Oil NOTE Change oi...

Страница 72: ...tingPin 4 O Ring 5 Plug 6 DowelPin 7 NeedleBearing 8 ValvePlate 9 SnapRing 10 SpringRetainer 11 Spring 12 Washer 13 CylinderBlock 14 SlipperPin 15 Guide 16 SlipperRetainer 17 CylinderPiston 18 PistonR...

Страница 73: ...Minimum and maximum displacement can be set with fixed internal stops The large diameter servo piston allows smooth acceleration and deceleration with relatively large circuit orificing Figure 3 15 Dr...

Страница 74: ...ench remove plug 3 3 Remove O rings 4 5 and 6 4 Using pliers remove centering springs 7 8 and 9 5 Remove spring retaining washers 10 and 11 6 Remove shift spool 12 7 Remove orifice poppet 13 INSPECTIO...

Страница 75: ...Description Action Checkoillevelinreservoirandoil supplytopump Insufficientamountofhydraulicfluidwillnotmeetsystemcooling demands Fillreservoirtoproperlevel Inspectheatexchanger if equipped Ifheatexch...

Страница 76: ...ny O rings on fit tings 9 Using an 11 16 inch hex wrench loosen speed sensor lock nut 14 if equipped Remove speed sensor using a Vi inch hex wrench Units without speed sensor have an O ring plug 15 in...

Страница 77: ...Remove valve plate 25 and timing pin 26 from end cap Each displacement has a unique valve plate For identification the last two digits of the valve plate part number are stamped on its surface 16 Rem...

Страница 78: ...ID DAMAGING SHAFT DURING SEAL REMOVAL INSTALL A LARGE SHEET METAL SCREW IN CHUCK OF SLIDE HAMMER DRIVE SCREW INTO SEAL SURFACE AND USE SLIDE HAMMER TO PULL SEAL 19 Turn housing over and remove snap ri...

Страница 79: ...Turn housing over and remove swashplate 39 by lifting on end opposite servo lever 23 Remove servo piston 40 Remove piston seal 41 and O ring 42 from servo piston Discard seal and O ring 24 Remove jou...

Страница 80: ...ully release pressure and remove outer block spring washer 50 block spring 52 and inner block spring washer 53 from cylinder block Inspection After disassembly wash all parts including end cap and hou...

Страница 81: ...ll not reduce thick ness below minimum specification SWASHPLATE AND JOURNAL BEARINGS Inspect running face servo ball joint and swashplate journal surfaces for damage or excessive wear Some material tr...

Страница 82: ...and servo pis ton ball socket for damage or excessive wear Replace as required LOOP FLUSHING SPOOL Inspect loop flushing spool for cracks or damage Replace as required Assembly 1 Install new O ring 1...

Страница 83: ...nsure concave sur face of retainer seats on ball guide If reusing pistons install them in original block bores Lubricate pistons slippers retainer and ball guide before assembly Set cylinder kit aside...

Страница 84: ...d bearings are properly seated Install cylinder kit 19 on shaft Install with slippers fac ing swashplate Rock the shaft to align block splines and slide cylinder kit into place Orient motor with shaft...

Страница 85: ...n place during installation 15 Install endcap 25 on housing with endcap screws 26 Ensure endcap will properly seat to housing without interference Improper assembly of internal compo nents may prevent...

Страница 86: ...Install shift spool 31 22 Install spring retaining washers on springs 32 and 33 23 Carefully install centering springs 34 35 and 36 24 Install new O rings 37 38 and 39 25 Using a 5 8 in wrench torque...

Страница 87: ...tor system pressure during start up 6 Watching pressure gauge and run engine at lowest pos sible speed until system pressure builds to normal levels minimum 160 psi 11 bar Once system pressure is esta...

Страница 88: ...SE OF THIS PROPER MAINTENANCE OF THE SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION NOTE This check is designed to replace the existing bearing bolt torque checks on JLG Lifts in service This check...

Страница 89: ...o insert the 0 0015 feeler gauge between the bolt head and hardened washer at the arrow indicated position c Lower the boom to horizontal and fully extend the boom d At the position indicated on Posit...

Страница 90: ...1 3 3 36 2 2 4 1 5 4 6 5 7 11 8 10 18 26 32 29 21 9 9 10 8 11 12 7 13 6 14 17 15 16 16 15 17 14 18 23 19 34 24 30 20 25 35 31 21 22 22 23 24 25 26 27 28 29 30 31 32 33 34 35 13 19 27 33 28 20 12 Figu...

Страница 91: ...Check dial indicator accuracy once positioned using a feeler gauge and ensure the dial indicator reading is the same as the feeler gauge thickness 5 Position the machine as follows and as seen in Fig...

Страница 92: ...SECTION 3 CHASSIS TURNTABLE 3 42 3121619 Figure 3 39 Swing Bearing Wear Tolerance...

Страница 93: ...SECTION 3 CHASSIS TURNTABLE 3121619 3 43 CEN TER OF GRAVITY 31 7 8 0 cm Upperstructure 39 000 lbs 17 690 kg Figure 3 40 Swing Bearing Removal Sheet 1 of 4...

Страница 94: ...SECTION 3 CHASSIS TURNTABLE 3 44 3121619 Figure 3 41 Swing Bearing Removal Sheet 2 of 4...

Страница 95: ...SECTION 3 CHASSIS TURNTABLE 3121619 3 45 Main Boo m Pivot CENTER OF GRAVITY B oom Assembly 21 650 lbs 9 82 0 kg Figure 3 42 Swing Bearing Removal Sheet 3 of 4...

Страница 96: ...N 3 CHASSIS TURNTABLE 3 46 3121619 Note Attach Lifting Device to Turntable Cutouts Closest to This Side of Turntable Turntable 15 350 lbs 6 963 kg 83 3 212 cm Figure 3 43 Swing Bearing Removal Sheet 4...

Страница 97: ...tilt setting is used in conjunction with the main boom length and when exceeded imposes the same func tionality as the 5 0 omni directional setting plus prevents boom telescope out The side tilt setti...

Страница 98: ...ng the engine or turbocharger ensure the turbo charger is pre lubed by adding clean engine oil into the turbo charger oil inlet until full After pre lubing crank the engine without firing engine fuel...

Страница 99: ...uced to 2 months NOTE DEF freezes at 12 F 11 C Cleaning and Flushing the Tank If contaminated fluid or foreign material is found in the tank the tank must be cleaned Use the following procedure for cl...

Страница 100: ...SECTION 3 CHASSIS TURNTABLE 3 50 3121619 Figure 3 44 Diesel Exhaust Fluid DEF Tank Sheet 1 of 2...

Страница 101: ...lTube 3 DEFFilter 4 Tie Wrap 5 RubberBushing 6 FloatAssembly 7 SuctionTube 8 SuctionStrengtheningPlate 9 ReturnTube 10 ReturnStrengtheningPlate 11 Connector 12 RubberHeader 13 Header 14 MetallicFlange...

Страница 102: ...A DRIVE PUMP FUNCTION PUMP GEAR PUMP SEE DETAIL B AIR FILTER SURGE TANK DOC SCR TANK VENT PORT FUEL RETURN FROM ENGINE SUPPLY FUEL LINE TANK TO PRE FILTER SEE DETAIL C FUEL SUPPLY PORT Figure 3 46 Eng...

Страница 103: ...AND RETURN FUEL LINE EMR4 HARNESS 140 AMP BATTERY ISOLATOR DETAIL B SUPPLY FUEL LINE INBOARD RETURN FUEL LINE OUTBOARD ENGINE HARNESS FUEL PUMP SUPPLY FUEL LINE FROM TANK DETAIL C Figure 3 47 Engine...

Страница 104: ...54 3121619 1001192266 F F SUPPLY PREFILTER TO FUEL PUMP DEF SUPPLY OUTLET TO DOSING MODULE DEF SUPPLY MODULE INLET FROM DEF TANK BACKFLOW TO DEF TANK Figure 3 48 Engine Installation and Diesel Exhaust...

Страница 105: ...1001192266 F COOLANT RETURN FROM DOSING MODULE COOLANT RETURN PORT COOLANT SUPPLY PORT COOLANT RETURN FROM DEF TANK COOLANT SUPPLY TO TEE FITTING UNDER ENGINE Figure 3 49 Engine Installation and Dies...

Страница 106: ...RNTABLE 3 56 3121619 1001192266 F L L L L SUPPLY FUEL LINE RETURN FUEL LINE DEF COOLANT SUPPLY LINE DEF COOLANT RETURN LINE DEF FLUID SUPPLY Figure 3 50 Engine Installation and Diesel Exhaust Fluid DE...

Страница 107: ...INE FROM DEF COOLANT VALVE INSTALL FUEL PUMP SUPPLIED WITH ENGINE SUPPLY FUEL LINE TO SECONDARY FUEL FILTER ON ENGINE TANK VENT HOSE DEF SUPPLY FROM OUTLET PORT ON SUPPLY MODULE DEF DOSING MODULE J J...

Страница 108: ...PPLY PORT DOSING MODULE VALVE TO BE ORIENTED WITH THE FLOW FACING THE FRONT CCW END OF THE MACHINE DEF COOLANT SUPPLY VALVE DEF COOLANT RETURN LINE COOLANT SUPPLY TO DEF COOLANT SUPPLY VALVE COOLANT S...

Страница 109: ...1 G PRESSURE SENSOR MIXING PIPE EXH GAS TEMP CONNECTION NOx SENSOR AFTER SCR O2 SENSOR O2 SENSOR STARTER CONNECTION ENGINE ECU CONNECTION PRE SCR NOx SENSOR DOC TEMP SENSOR GLOW PLUG CONNECTION Figure...

Страница 110: ...SECTION 3 CHASSIS TURNTABLE 3 60 3121619 Figure 3 54 Engine Electrical Circuit...

Страница 111: ...ulphur content may not be used in engines with exhaust gas after treatment Fuels with a sulphur content 1 0 m m are not permissible due to high corrosion and considerable shortening of the engine life...

Страница 112: ...NOx using ammonia as a reductant within a catalyst system The chemi cal reaction is known as reduction where the DEF is the reducing agent that reacts with NOx to convert the pollutants into nitrogen...

Страница 113: ...ing will be stopped immediately if The Platform Ground Select switch is switched from Ground to Platform mode Function switch is enabled to perform a boom function The Engine is powered down If Mainte...

Страница 114: ...eepandDTC active 3 ShutOff Level 1125 Blinking 3Hz IdleLock Boom FunctionsLocked OutandTrappedin Transport ContactDeutzDealer Table 3 9 Cleaning When Crystallization is Detected During SCR Crystalliza...

Страница 115: ...nsA01 K74 K91and orreflashECU Iferrorisstillpresent exchangeECU 43 731 523925 4 Shortcircuittogroundactuatorrelais3 OverloadatPinsO_V_RH3x A88 K57 Suspectedcomponents 1 PinA88 Preheatrelay Exhaustflap...

Страница 116: ...tioncableandif necessaryrepairorreplaceit checkresistancein CANlines 120Ohm 88 223 102 2 Chargeairpressuremessuredbysensoris abovetheshutoffthreshold Chargedaircoolerpressurebelowthreshold Checkwasteg...

Страница 117: ...CAN BUS 130 597 3224 9 TimeoutErrorofCAN Receive Frame AT1IG1Vol NOXsensor SCR system upstreamcat DPF systemdownstreamcat FailureoftheCANBusmessage NOXsensorandsensorconnectioncheck 133 766 523938 9 T...

Страница 118: ...ANBusmessage Checkwiringharnessandcustomerdevices 179 527 523240 9 TimeoutCAN messageFunModCtl Func tionModeControl TimeoutError MissingCANBusmessage CheckCANBuscabling Bussheduling polarity shortcirc...

Страница 119: ...nginespeedcalculated byECUisabovethetargetrange theECU activatesasystemreaction Overspeedmonitoringduring1levelofFOC Failureoverruncondition ifenginespeed wasoverLimit checkpowertrainsettingsregarding...

Страница 120: ...ensordefect Checkofwiringandwaterinfuelsensor Checkcabling ifchargeWaterinFuelsensoris notworking checksensorandif necessaryreplaceit checkconnectioncableandifnecessaryrepair orreplaceit 465 228 97 4...

Страница 121: ...trisationofinjector adjustmentcyl 3 ThresholdforerrordetectionisaninternalECU threshold Checkcorrectinjectoradjustmentvalue IMA 562 1 5 8 523898 13 Missingorwronginjectoradjustmentvalue programming IM...

Страница 122: ...ectorcylinder1 wiringharness cablebreakorshortcircuit sen sordefective connectioncable damaged ThresholdforerrordetectionisaninternalECU threshold Checkwiringharness injectorsandifnecessary repair rep...

Страница 123: ...old Checkwiringharnessandmeteringunitifnec essaryrepair replaceit 597 135 523615 4 Fuelmeteringunit thecurrentdrainmea suredbyECUisabovethetargetrange shortcircuittogroundlowside Thresholdforerrordete...

Страница 124: ...3612 12 Internalhardwaremonitoring theCPUof theECUisresetandthecauseisloggedinter nally noitemwillbecreatedinerrormem ory Errorinthecheckoftheshut offpathtestofthe undervoltagedetection ECUinternal er...

Страница 125: ...g timewithmaximumpermittedenergising time Diagnosticfaultchecktoreporttheerror duetoOver Run ThresholdforerrordetectionisaninternalECU threshold Iferrorisstillpresent exchangeECU 638 555 523612 12 Err...

Страница 126: ...e shortcircuittobatteryorcablebreak checkbatteryandwiring Checkcabling Ifsensornotworking checksen sorandifnecessaryreplaceit checkconnectioncableandifnecessaryrepair orreplaceit 733 224 100 4 Oilpres...

Страница 127: ...isoutofthetarget range TheSensorVoltageisabovetheThreshold Checkcabling ifchargeairpressure tempera turesensorisnotworking checksensor andifnecessaryreplaceit checkconnection cableandifnecessaryrepair...

Страница 128: ...laceit 825 253 523009 9 Thepressurereliefvalve PRV hasreached thenumberofallowedactivations Railpressurehasexceededthetriggerthresh oldofthepressurelimitingvalve Replacepressurereliefvalve PRV andrese...

Страница 129: ...einrailcalcu latedbyECUisbelowthetargetrangewhich isdependantontheenginespeed Pressuregovernordeviationexceedsthelimit ingvaluebasedontheenginespeed ThresholdforerrordetectionisaninternalECU threshold...

Страница 130: ...suredbyECUisoutofthetargetrange Checkcabling checkrailpressuresensorandif necessaryreplaceit checkconnectioncableandifnecessaryrepair orreplaceit Checkcabling checkrailpressuresensorandif necessaryrep...

Страница 131: ...l Thesignalexceedstheapplicatablethreshold signalrangeviolation Ifthesignalisbelowtheapplicatablethreshold APP_uRawSRCHiHTLIS_C thesignal rangeviolationisreset afterthehealingdebouncing IncasewhentheC...

Страница 132: ...movable changeECU 947 282 1080 13 Internalhardwaremonitoring theECU detectsadeviationofthetargetrangeofthe powersupplyvoltageofsensoroutput2 SuspectedcomponentsEDC17cv52 PinK16 secondfootpedal PinA20...

Страница 133: ...edbyECUisabovethetar getrange ShortcutLowSide Outputtoground ThresholdforerrordetectionisaninternalECU threshold Checkcablingandstartrelayandifnecessary replaceit checkconnectioncableofterminal50andif...

Страница 134: ...sensorrawsignalAir_uRawTCACDs volt age isbelowAir_SRCTCACDs uMin_C CheckCAC sensorandifnecessaryreplaceit checkconnectioncableandif necessaryrepairorreplaceit 996 233 105 0 Chargeairtemperaturedownstr...

Страница 135: ...ordetection deviationfrom setpoint 7 TroubleshootingwithSERDIA2010UseCase EGRDiagnostic 1022 5 9 4 5763 6 ActuatorerrorEGR Valve signalrangecheck high measuredcurrentbyECUisovertarget Shortcircuittoba...

Страница 136: ...sitionupstreamDOC not upstreamSCRordownstreamDOC CheckTupstreamDOCsensor CheckotherT sensorswithinEAT system Exh_tOxiCatDs UCatUsT_tFlt_mpshow plausiblevalues Noerrorsonthem 1039 683 4765 0 Theexhaust...

Страница 137: ...eraturesensor thevoltageofsensormeasuredbyECUisout ofthetargetrange VoltageoftemperaturesensorupstreamSCR catalyst minimumlimit Shortcircuittoground Checksensor Checkwiring ReplaceUCatUsT sensor 1075...

Страница 138: ...tcuttogroundorbrokenwiring broken heatingelementinpressureline ThresholdforerrordetectionisaninternalECU threshold Checkwiring Checkheatingelement 1098 676 523718 5 Ureaheaterrelay thecurrentdrainmea...

Страница 139: ...Uisabovethetargetrange Shortcuttobattery Ifthiserrordetectedduringtheheatingphaseis aresulterror KWP1089 Brokenwiring Ureatankheatingvalvedefect ThresholdforerrordetectionisaninternalECU threshold Che...

Страница 140: ...essuresensor the currentdrainmeasuredbyECUisabovethe targetrange Shortcuttobattery Brokenwiring Pressuresensorinureasupplymoduledefect Checkwiring Checkpressuresensorinureasupplymodule 1128 665 523632...

Страница 141: ...nvT_t About 40 C IfyesErrorcouldbeplausible CheckureatanktemperatureSCR_tSensUTnkT CheckwiringofanalogDEFT Levelsensor CheckanalogDEFT Levelsensor 1137 6 6 9 4365 2 SignalerrorincaseofUreatanktemperat...

Страница 142: ...se 1226 594 5763 3 ActuatorEGR valve shortcuttobatteryis detected Short Circuittobatteryoncomponentwiring ThresholdforerrordetectionisaninternalECU threshold Checkwiring component ECU CheckrepairwithS...

Страница 143: ...togroundoncylinder bank0 Short Circuittogroundoncomponentwiring Checkwiring component ECU Note affectedinjectorhastobeevaluated accordingtofiringorder 1340 566 2798 4 Injectortest Shortcuttogroundoncy...

Страница 144: ...2 Lowfuelpressure thelowfuelpressurecal culatedbyECUisunderneaththetarget range theECUactivatesasystemreaction Fuelpressurebelowwarningthreshold ThresholdforerrordetectionisaninternalECU threshold Ch...

Страница 145: ...mounting Ifwaterinside replacesen sor Checkmountingpositionofsensorandjudgeit regardingcondensewaterformation agglomeration Checkwiringharness Exchangesensor 1537 255 524078 9 LambdavalueofNOx Sensord...

Страница 146: ...heckLambdavaluesofNOx sensorupstream SCRcatalystatatidleconditions ComRxSCR_rCanLamUs_mp Threshold ComparetoComRxSCR_rCanLamDs_mp Must bealmostidentical CheckCANBusofNOx sensorupstreamSCRcat alyst Che...

Страница 147: ...1 SCRHtr_rUHtrMeasRatio_mp Threshold 2 Short Circuittobatteryonwiringtocomponent Checkwiring component 1559 869 524063 4 Connectionbetweenheatingvalve Y31 on thecontrolunitPinA 92and LoadsideSCRheater...

Страница 148: ...ken ExchangeSCR Cat alyst 1566 892 524065 1 Therelativpressurevalueoftheexhaustgas fromtheureacatupstreamsensorisless thananapplicableminimumpressure threshold sensedpresureupstreamSCRcatalyst physi c...

Страница 149: ...leminimum heatertemperaturethresholdofthesupply module ThetemperatureisreadoutviathePWMsig naloftheureapump Thatisonlypossiblein statusinitoftheSCR systemshortafterigni tionwasswitchedon Whenthatstate...

Страница 150: ...aldefectatthefloatgauge Checklevelsensorandfloatgauge 1594 129 1761 1 TheDEFtanklevelsensordetectsavalue lowerthantheminimumallowedthreshold Suspectedcomponents UreaQualitySensordefect mechanicaldefec...

Страница 151: ...pressuresensor Atignitiononand SCRsystemstate 0 Initcheck SCR_pAbsAdapUPmpPshallbeidenticalto EnvP_p Fulfilled Sensorokay Checkrevertingvalve see DFC_SCRCoRevVlvBlk Checkpumpfilter dirtinside Suspecte...

Страница 152: ...sage PGN65348 Themessageisnotreceived ThresholdforerrordetectionisaninternalECU threshold CheckCANBUSEATControlReceiveMessage PGN65348 CM1ModuleCustomerRecieveMessage 1683 9 4 5 524121 9 Timeouterroro...

Страница 153: ...ratureabovethresh old overheatingofEGRactuator LetEGRactuatorcooldown checkheataccu mulationduringworstcaseoperation 1763 415 2791 0 Internalactuatortemperatureisabove threshold OverheatingofEGRactuat...

Страница 154: ...Status_mp 1 Thiserrorshowsup ifnoproperureapresure couldbebuildupwithintheSCRsystem state FillLines SCRCo_stStatus_mp 1 3casescanleadtotheerror CaseA increasingpressureisdetectedwithin 15sthecheckhasp...

Страница 155: ...tails Erroratdynamicplausibilitycheck temperaturedifferenceofsensedtempera tureupstreamSCRcatalystandambient temperature asdynamicplausibilitylimit dynamiccheckisblockedifstaticplausibility checkisalr...

Страница 156: ...ensordefect Supplymoduletemperaturesensordefect ProblematSupplymoduleunit broken exchangesupplymodule 1868 894 524067 2 absolutediferenceofsensedtemperatureof supplymoduletemperatureandambient tempera...

Страница 157: ...eand atcorrectpositions CheckthepositionofthesensorupstreamSCR whichmightbephysicallymountedin thewrongposition Ifcoldstartconditioncanbemadesure engine wasoffforatleast8h compare valuesofEnvT_t EngDa...

Страница 158: ...eachrequiredtem peraturelevel Checkengineairpath IntakeTrottle EGR Valve andturbochargerokay Anyleakageinengineairintakesytemor exhaustgassystem Checktemperaturesensorswithinexhaustsys tem upstreamDOC...

Страница 159: ...fference 10Kafter25min stand stillmainphase 590 Cdownstream DOCarenotreached exchangeDOC Verybigdifference 100Kafter25minstand stillmainphase 590 Cdownstream DOCexceeded checkinjectionsystemof engine...

Страница 160: ...tanktemperature fillinggradeandDEF qualityanditisalsoanCANsensor no PIN Wrongdiagnosticoftheshortcircuitslogic insidethetemperaturesensoroftheUQS CANCommunicationcorrupted Checkthewiringtothesuctionu...

Страница 161: ...orcrystallisation DoestheNOx Sensorsworkproperly Compare ComRxSCR_rNOxUsto ComRxSCR_rNOxDs when ComRxSCR_stNOxRdyUs 1 ComRxSCR_stNOxRdyDs 1 Warmengine andEAT system SCRT_tCatAvrgExhGs_mp 250 C SCR_stS...

Страница 162: ...s DEFqualitysensor DEF CheckDEFqualityand orDEFqualitysensor 1908 277 3519 13 TemperatureatUQSoutofrangethespeci fiedthresholds invalidqualityofthetem perature SuspectedComponents Tankheater DEFsensor...

Страница 163: ...aining sensor or switch In addition for a failure of either jib transport length switch jib length will be determined by the remaining switch This system is used to control the following systems Beyon...

Страница 164: ...sult in reduced function speeds BCS warning light illumination and restriction of functions The platform alarm will sound and the BCS light will flash with attempts to operate restricted functions The...

Страница 165: ...racking function ality can be turned off using the manual position of the boom control select switch Slow Down System When the main boom approaches the edges of the working envelope all functions exce...

Страница 166: ...All functions will default to creep speed if in platform mode and the boom is out of the transport position To reset the fault the emergency stop switch should be recy cled Boom Control Select The bo...

Страница 167: ...ground module loses CAN communication with both the Jib Control Module and the Platform module in the case of a sev ered boom cable for example This mode allows the boom to be lifted down and telesco...

Страница 168: ...bled to recover the boom After the boom is brought down it will be trapped into transport Reset or turning it off is achieved by escaping out of the service mode by cycling power to the machine or re...

Страница 169: ...SECTION 4 BOOM PLATFORM 3121619 4 7 Figure 4 1 Boom Hydraulic System...

Страница 170: ...pin Lower the lift cylinder down until it rests on the boom rest 7 Use an overhead crane or similar lifting device to sup port the rear of the boom 8 Remove the boom pivot pin 9 Carefully lift the bo...

Страница 171: ...m Sec tion 5 is the fly NOTE During Assembly Super Lube lubricant JLG p n 3020042 is to be moderately applied to all four inner surfaces of both ends of each boom section to a minimum depth of three t...

Страница 172: ...with JLG threadlocking com pound P N 0100011 and secure the wear pads with the bolts and washers Torque the bolts to 40 5 ft lbs 55 Nm 4 Install the section 5 retract ropes to into the holes in the si...

Страница 173: ...SECTION 4 BOOM PLATFORM 3121619 4 11 Figure 4 2 Boom Assembly Sheet 1 of 9...

Страница 174: ...SECTION 4 BOOM PLATFORM 4 12 3121619 Figure 4 3 Boom Assembly Sheet 2 of 9...

Страница 175: ...SECTION 4 BOOM PLATFORM 3121619 4 13 Figure 4 4 Boom Assembly Sheet 3 of 9...

Страница 176: ...SECTION 4 BOOM PLATFORM 4 14 3121619 Figure 4 5 Boom Assembly Sheet 4 of 9...

Страница 177: ...SECTION 4 BOOM PLATFORM 3121619 4 15 Figure 4 6 Boom Assembly Sheet 5 of 9...

Страница 178: ...SECTION 4 BOOM PLATFORM 4 16 3121619 Figure 4 7 Boom Assembly Sheet 6 of 9...

Страница 179: ...SECTION 4 BOOM PLATFORM 3121619 4 17 Figure 4 8 Boom Assembly Sheet 7 of 9...

Страница 180: ...SECTION 4 BOOM PLATFORM 4 18 3121619 Figure 4 9 Boom Assembly Sheet 8 of 9...

Страница 181: ...SECTION 4 BOOM PLATFORM 3121619 4 19 Figure 4 10 Boom Assembly Sheet 9 of 9...

Страница 182: ...SECTION 4 BOOM PLATFORM 4 20 3121619 Figure 4 11 Locations for Threadlocker Application Sheet 1 of 5...

Страница 183: ...SECTION 4 BOOM PLATFORM 3121619 4 21 Figure 4 12 Locations for Threadlocker Application Sheet 2 of 5...

Страница 184: ...SECTION 4 BOOM PLATFORM 4 22 3121619 Figure 4 13 Locations for Threadlocker Application Sheet 3 of 5...

Страница 185: ...SECTION 4 BOOM PLATFORM 3121619 4 23 Figure 4 14 Locations for Threadlocker Application Sheet 4 of 5...

Страница 186: ...SECTION 4 BOOM PLATFORM 4 24 3121619 Figure 4 15 Locations for Threadlocker Application Sheet 5 of 5...

Страница 187: ...SECTION 4 BOOM PLATFORM 3121619 4 25 Figure 4 16 Boom Assembly Torque Values Sheet 1 of 4...

Страница 188: ...SECTION 4 BOOM PLATFORM 4 26 3121619 Figure 4 17 Boom Assembly Torque Values Sheet 2 of 4...

Страница 189: ...SECTION 4 BOOM PLATFORM 3121619 4 27 Figure 4 18 Boom Assembly Torque Values Sheet 3 of 4...

Страница 190: ...SECTION 4 BOOM PLATFORM 4 28 3121619 Figure 4 19 Boom Assembly Torque Values Sheet 4 of 4...

Страница 191: ...ds and shims to section 4 Coat the retaining bolts with JLG threadlocking com pound P N 0100011 and secure the wear pads with the bolts and washers Torque the bolts to 28 ft lbs 38 Nm 13 Install the f...

Страница 192: ...ave retaining bolts to 178 ft lbs 241 Nm Torque the sheave plate retainer block bolts to 40 5 ft lbs 55 Nm 22 Install the section 4 extend ropes to section 4 NOTE Boom section 3 weighs approximately 2...

Страница 193: ...ts with JLG Threadlocker P N 0100011 and install the section 5 retract ropes to section 3 using the nuts keeper plates bolts and washers 27 Coat the bolts with JLG Threadlocker P N 0100011 and install...

Страница 194: ...with JLG Threadlocker P N 0100011 Install the rope retaining blocks to the front of section 3 using washers bolts and nuts 31 Coat the bolts with JLG Threadlocker P N 0100011 Install the front side we...

Страница 195: ...r Lube lubricant JLG p n 3020042 to all 4 sides of the boom approximately 3 to 4 feet on both ends Apply Super Lube to section 3 on the end that will go into section 2 only Apply super lube to all out...

Страница 196: ...r wear pads after they are installed Slide sections 2 3 4 and 5 as an assembly into section 1 using proper lifting procedures NOTE Position the deflectors so the surface is 3 4 mm from the section 2 b...

Страница 197: ...ng the telescope cyl inder barrel trunnion blocks to boom section 2 and remove the trunnion blocks 4 Remove the bolts securing the adjustment mount and disconnect the adjustment mount from boom sectio...

Страница 198: ...e bottom wear pad s on Section 5 boom as specified on the boom assembly drawing 4 Install the top wear pad s on Section 5 boom and shim as required to obtain the total dimension 0 to1 16 under the cor...

Страница 199: ...ness for machines that are used in excessively dirty environments 1 JLG recommends the use of the JLG Hostile Environment Package if available to keep the internal portions of a boom cleaner and to he...

Страница 200: ...and cables until they are resting against the flat bars on the outside radius of the power track Force additional hydraulic hose slack into the power track by pushing the hoses from the Location E Ti...

Страница 201: ...SECTION 4 BOOM PLATFORM 3121619 4 39 Figure 4 20 Hose Adjustment...

Страница 202: ...SECTION 4 BOOM PLATFORM 4 40 3121619 Figure 4 21 Section 3 Boom Cables...

Страница 203: ...SECTION 4 BOOM PLATFORM 3121619 4 41 Figure 4 22 Section 4 Boom Cables...

Страница 204: ...SECTION 4 BOOM PLATFORM 4 42 3121619 Figure 4 23 Section 5 Boom Cables...

Страница 205: ...SECTION 4 BOOM PLATFORM 3121619 4 43 Figure 4 24 Jib Hydraulics Sheet 1 of 7...

Страница 206: ...V1 T V2 JIB STOW ROTATOR P L2 L1 T2 R1 R2 S1 S2 T1 FRONT VIEW OF PLATF ORM CONT ROL VALVE JIB LOC K CYLINDER V1 V2 JIB LEVEL CYLINDER V1 V2 JIB LIF T CYLINDER V1 V2 JIB TELESCOPE CYLIND ER V1 V2 PLAT...

Страница 207: ...SECTION 4 BOOM PLATFORM 3121619 4 45 PLATFORM LEVEL CYLINDER PL ATFOR M VALVE JIB LOCK C YL INDER JIB CONTR OL VALVE JIB TELE CYLIND ER PORT BLOCK 10011 57243 C Figure 4 26 Jib Hydraulics Sheet 3 of 7...

Страница 208: ...SECTION 4 BOOM PLATFORM 4 46 3121619 PLATFORM VALVE JIB LOCK CYLINDER JIB CONTROL VALVE Figure 4 27 Jib Hydraulics Sheet 4 of 7...

Страница 209: ...SECTION 4 BOOM PLATFORM 3121619 4 47 PLATFORM VALVE 10 0115 7243 C Figure 4 28 Jib Hydraulics Sheet 5 of 7...

Страница 210: ...CTION 4 BOOM PLATFORM 4 48 3121619 0 75 AIR LINE 0 815 GEN CABLE 0 7 CONTROL CABLE 0 75 AIR LINE 0 81 5 GEN C ABLE 25 POWER CABLE 2 5 POWER CABL E 1001 1572 43 C Figure 4 29 Jib Hydraulics Sheet 6 of...

Страница 211: ...319 195 271 313 382 423 324 362 382 300 MAINTAIN H OSE LOOP AT THIS DIMENSION 1600 PULLED LENGTH OF H OSES STRETCH H OSE OUT AN D MEASURE IN A STRAIGHT LINE NOTE AL L DIMEN SIONS IN MM 379 389 459 401...

Страница 212: ...the hydrau lic hoses that run from the boom to the jib control valve It may be necessary to disconnect additional lines to gain access to certain fittings Cap or plug all openings 5 Unbolt the valve f...

Страница 213: ...in place with the keeper pin and bolt Torque the bolt to 165 ft lbs 224 Nm 5 Place the mounting bracket on the jib valve and bolt the jib valve to the fly boom section 6 Install the wiring harnesses a...

Страница 214: ...N 0100019 HOSE CLAMP RUBBER PAD RUBBER PAD BOLT KEEPER PIN TORQUE 120 FT LBS 163 Nm BOLT KEEPER PIN BOLT KEEPER PIN SCREW COVER BOLT KEEPER PIN TORQUE 60 FT LBS 82 Nm TORQUE 25 FT LBS 34 Nm PLATFORM L...

Страница 215: ...adlocker PN 0100011 JLGThreadlocker PN 0100019 BOLT BOLT BOLT SHIMS JIB PIVOT JIB LIFT CYLINDER JIB ROTATE ACTUATOR TORQUE 190 FT LBS 260 Nm TORQUE 340 FT LBS 460 Nm BOLT KEEPER PIN TORQUE 120 FT LBS...

Страница 216: ...ESS FIT JIB ROTATOR BEARING HOUSING JIB PIVOT BEARING HOUSING JIB PIVOT BEARING HOUSING SECTION A A ALIGN CUTOUT IN CAP LOCK PIN CYLINDER CAP AS SHOWN Loctite RC 609Threadlocker TORQUE 180 FT LBS 245...

Страница 217: ...Threadlocker ORIENT PORT ON LOCK CYLAS SHOWN JIB PIVOT BEARING BEARING BEARING PIVOT PAD MOUNT JIB ROTATOR BOTTOM PLATE TORQUE BOLTS TO 20 FT LBS BOLT SHIMS WEAR PADS JIB ROTATE ACTUATOR GUIDE BLOCK B...

Страница 218: ...between the wear pad and pivot pad mount 3 Add shims as required to fill the gap between the wear pad and the edge of the side plate of the jib rotator 4 Shim until the distance between the jib and t...

Страница 219: ...vement NOTE Delayed movement of the fly boom indicates loose wire ropes 12 Year or 7000 Hour Replacement 1 Mandatory wire rope and sheave replacement Additional inspection required if a Machine is exp...

Страница 220: ...4 followed by section 5 Use the Boom Telescope function to position the boom sec tions Using the wire rope adjustment nuts to position the boom sections will cause damage to the wire rope adjust ers 1...

Страница 221: ...SECTION 4 BOOM PLATFORM 3121619 4 59 Figure 4 37 Initial Exposed Thread Length for Wire Rope Adjustment...

Страница 222: ...e equal to what the section needs to move to be within tolerance for example if the section must move 0 5 inches to fall within the dimension shown tighten the nut so it moves 0 5 inches further from...

Страница 223: ...ion 4 Repositioning BOOM SECTION 4 REPOSITIONING 1 If Boom Section 4 falls within the dimension and toler ance shown in Figure 4 36 with the boom fully retracted proceed to Boom Section 5 Repositionin...

Страница 224: ...exposed end of the adjustment stud e Retract the boom assembly such that the platform moves 2 to 3 feet 0 6m 0 9m from the previous extended position in step c f Tighten the Section 4 Extend Adjustmen...

Страница 225: ...the Section 5 Retract Adjustment Nuts shown below moving them a distance equal to what the section needs to move to be within toler ance E g If the section must move to fall within the dimension show...

Страница 226: ...ions and tolerances shown in Figure 4 36 If the boom sections have been properly positioned but there is not enough adjustment travel remaining on a wire rope to achieve proper torque the service life...

Страница 227: ...the two ropes until both maintain the required torque 10 Using tool JLG p n 1001162216 torque Section 4 Extend Adjustment Nuts to 17 ft lb 23 Newton meters alternating between the two ropes until both...

Страница 228: ...t Function Exercise the boom telescope function When wire ropes are properly torqued all traveling sections will move simultane ously when extending and retracting Re Assembly 1 Install nylon collar l...

Страница 229: ...esponsibility of the operator to take immediate action To avoid damaging the proximity switch install and adjust after assembling the switch block compression spring and torquing the wire ropes Adjust...

Страница 230: ...SECTION 4 BOOM PLATFORM 4 68 3121619 1 Powertrack 2 Powertrack 3 Clamp Plate 4 Rubber Pad 5 Powertrack 6 Clamp Plate 7 Rubber Pad Figure 4 40 Powertrack Installation Sheet 1 of 4...

Страница 231: ...SECTION 4 BOOM PLATFORM 3121619 4 69 1 Clamp Plate 2 Rubber Pad 3 Clamp Plate 4 Rubber Pad 5 Clamp Plate 6 Rubber Pad Figure 4 41 Powertrack Installation Sheet 2 of 4...

Страница 232: ...pport 5 Track Support Cover 6 Spacer Tube 7 Power Track Support 8 Track Support Cover 9 Power Track Support 10 Track Support Cover 11 Support Bracket 12 Support Bracket 13 Support Bracket 14 Hose Cove...

Страница 233: ...ush Tube Pad 3 Push Tube Pad 4 Upper Push Tube Assembly 5 Adjusting Shims 6 Mounting Plate 7 Adjusting Shims 8 Lower Push Tube Assembly 9 Adjusting Shims 10 Mounting Plate 11 Adjusting Shims 12 Suppor...

Страница 234: ...SECTION 4 BOOM PLATFORM 4 72 3121619 Figure 4 44 Powertrack Shimming Instructions...

Страница 235: ...SECTION 4 BOOM PLATFORM 3121619 4 73 Figure 4 45 Powertrack Locations for Threadlocker Application and Torque Sheet 1 of 4...

Страница 236: ...SECTION 4 BOOM PLATFORM 4 74 3121619 Figure 4 46 Powertrack Locations for Threadlocker Application and Torque Sheet 2 of 4...

Страница 237: ...SECTION 4 BOOM PLATFORM 3121619 4 75 Figure 4 47 Powertrack Locations for Threadlocker Application and Torque Sheet 3 of 4...

Страница 238: ...SECTION 4 BOOM PLATFORM 4 76 3121619 Figure 4 48 Powertrack Locations for Threadlocker Application and Torque Sheet 4 of 4...

Страница 239: ...SECTION 4 BOOM PLATFORM 3121619 4 77 Figure 4 49 Powertrack Hose Installation Sheet 1 of 4...

Страница 240: ...SECTION 4 BOOM PLATFORM 4 78 3121619 Figure 4 50 Powertrack Hose Installation Sheet 2 of 4...

Страница 241: ...SECTION 4 BOOM PLATFORM 3121619 4 79 Figure 4 51 Powertrack Hose Installation Sheet 3 of 4...

Страница 242: ...SECTION 4 BOOM PLATFORM 4 80 3121619 Figure 4 52 Powertrack Hose Installation Sheet 4 of 4...

Страница 243: ...ntenance 1 Place the powertrack on a workbench 2 Remove the screws from the bars on one side of the powertrack on the first link 3 Remove the screws from the flat bar on the other side of the powertra...

Страница 244: ...1619 5 Slide the poly roller off of the round bar 6 Hold the round bar to remove the other screw 7 Slide the flat bar out 8 Remove the snap ring from one side of the bracket 9 Remove the snap ring fro...

Страница 245: ...and slide the bracket side up and over the extrusion on the link 11 Repeat the previous step on the other side 12 Slide the bracket off of the powertrack Two Piece Bracket Maintenance 1 Loosen the scr...

Страница 246: ...snap rings and pins 6 Remove the screws from the bar Remove the snap ring and pin 7 Slide the link out Snap Rings and Screws WHEN PERFORMING MAINTENANCE ON THE POWERTRACK MAKE SURE TO DISCARD AND REP...

Страница 247: ...p ring is shown below A snap ring that is not seated is shown below A seated and closed snap ring is shown below 10 24 x 0 812 button torx socket head with blue locking patch Tighten to 45 50 in lbs 5...

Страница 248: ...N 4 BOOM PLATFORM 4 86 3121619 C D E A B C D E Torqueto40ft lbs 55Nm Loctite 242 Torqueto586ft lbs 795Nm Checktorqueevery150hoursofoperation Torqueto85ft lbs 116Nm Figure 4 53 Platform Support Torque...

Страница 249: ...FORE RETURNING TO SERVICE REFER TO THE SERVICE MANUAL FOR REMOVAL AND INSTALLATION PROCEDURES THE EXTERNAL FALL ARREST SYSTEM REQUIRES AN ANNUAL INSPECTION AND CERTIFICATION THE ANNUAL INSPECTION AND...

Страница 250: ...belleville washers washer retain ing nut and jam nuts Orient the hardware as shown below and with the belleville washers so the gap is pres ent at the outside diameter of the washers install the nuts...

Страница 251: ...ION 4 BOOM PLATFORM 3121619 4 89 I 8 7 1 2 3 4 6 9 5 Figure 4 55 Bolt On External Fall Arrest System 1 BellevilleWasher 2 Washer 3 HexNut 4 JamNut 5 LHBracket 6 AttachmentRing 7 Cable 8 RHBracket 9 De...

Страница 252: ...SECTION 4 BOOM PLATFORM 4 90 3121619 NOTES...

Страница 253: ...prior to assembly Cup and Brush The following is needed to correctly oil the o ring in this man ner A small container for hydraulic oil Small paint brush 1 Hold the fitting in one hand while using the...

Страница 254: ...d drip from the bottom of the fitting This should signify an even coating of oil on the fitting 3 O ring Boss type fittings will require more pressure in able to immerse more of the fitting into the s...

Страница 255: ...nnections JIC 37 flare per SAE J514 SAE 45 flare per SAE J512 ORFS o ring face seal per SAE J1453 MBTL metric flareless bite type fitting pressure rating L medium per ISO 8434 DIN 2353 MBTS metric fla...

Страница 256: ...will no longer thread onto the mating part when tightened by hand or fin gers Finger Tight is relative to user strength and will have some variance The average torque applied by this method is 3 ft l...

Страница 257: ...owever care should be taken not to introduce sealant into the system d Avoid applying sealant to the area of the threads where the sealant will be forced into the system This is generally the first tw...

Страница 258: ...ber of turns per Table 5 1 NPTF Pipe Thread See FFWR and TFFT Methods for TFFT procedure requirements NOTE TFFT values provided in Table 5 1 NPTF Pipe Thread are applicable for the following material...

Страница 259: ...fitting the number of turns per Table 5 2 BSPT Pipe Thread See FFWR and TFFT Methods for TFFT procedure requirements NOTE TFFT values provided in Table 5 2 BSPT Pipe Thread are applicable for the fol...

Страница 260: ...D THE LUBRICATION WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE 3 Torque assembly to value listed in Table Table 5 3 37 Flare JIC Thread Steel or Table 5 4 37 Flare JIC Thread Aluminum...

Страница 261: ...11 60 0 50 12 70 14 15 15 19 20 21 1 to1 1 2 6 9 16 18 0 51 13 00 0 56 14 30 22 23 24 30 31 33 1 to1 1 2 8 3 4 16 0 69 17 60 0 75 19 10 42 44 46 57 60 63 1 1 2to1 3 4 10 7 8 14 0 81 20 50 0 87 22 20...

Страница 262: ...1 2 20 0 46 11 60 0 50 12 70 9 10 10 12 13 14 1 to1 1 2 6 9 16 18 0 51 13 00 0 56 14 30 14 15 16 19 20 21 1 to1 1 2 8 3 4 16 0 69 17 60 0 75 19 10 27 29 30 37 39 41 1 1 2to1 3 4 10 7 8 14 0 81 20 50 0...

Страница 263: ...ICATION OR SEALANT IS REQUIRED THE LUBRICATION WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE Torque fitting to value listed in Table 5 5 45 Flare SAE Steel and Table 5 6 45 Flare SAE A...

Страница 264: ...25 00 1 06 27 00 84 88 92 114 119 125 Aand Bthreaddimensionsforreferenceonly SeeFFWRandTFFTMethodsforFFWRprocedurerequirements Table 5 6 45 Flare SAE Aluminum Brass TYPE FITTING IDENTIFICATION Torque...

Страница 265: ...ig uration of the connection ALUMINUM BRASS FITTINGS OR ALUMINUM BRASS MATING COMPONENTS indicate either the following material configu rations STEEL fittings with ALUMINUM or BRASS mating compo nents...

Страница 266: ...3 4 6 11 16 16 0 63 15 90 0 69 17 50 20 21 22 27 28 30 1 4to1 2 1 2to3 4 8 13 16 16 0 75 19 10 0 81 20 60 26 28 29 35 38 39 1 4to1 2 1 2to3 4 10 1 14 0 94 23 80 1 00 25 40 39 41 43 53 56 58 1 4to1 2 1...

Страница 267: ...are If necessary replace fitting or tube 2 Lubricate thread and cone of fitting body or hardened pre assembly tool as well as the progressive ring and nut threads 3 Slip nut and progressive ring over...

Страница 268: ...1 5to1 75 22 M30x2 27 90 30 00 7 50 22 20 1 5to1 75 28 M36x2 33 90 36 00 7 50 28 20 1 5to1 75 35 M45x2 42 90 45 00 10 50 35 30 1 5to1 75 42 M52x2 49 90 52 00 11 00 42 30 1 5to1 75 TYPE Tube O D Thread...

Страница 269: ...splatter splits burrs or other foreign material If necessary replace fitting or adapter 2 Remove the locknut from the bulkhead assembly 3 Insert the bulkhead side of the fitting into the panel or bulk...

Страница 270: ...5 142 149 183 193 202 14 15 16 12 170 179 187 230 243 254 16 17 16 12 200 210 220 271 285 298 20 111 16 12 245 258 270 332 350 366 24 2 12 270 284 297 366 385 403 TYPE Dash Size Thread Size Torque Ft...

Страница 271: ...39 47 50 53 15 M22x1 5 44 47 50 60 64 68 18 M26x1 5 70 75 80 95 102 108 22 M30x2 115 120 125 156 163 169 28 M36x2 150 157 164 203 213 222 35 M45x2 155 162 169 210 220 229 42 M52x2 220 230 240 298 312...

Страница 272: ...fer to Adjustable Stud End Assembly for proper assembly 6 Torque the fitting or nut to value listed in Table 5 12 thru Table 5 17 while using the Double Wrench Method a The table headings identify the...

Страница 273: ...87 47 60 305 321 336 415 435 456 32 21 2 12 2 50 63 50 375 394 413 510 534 560 TYPE FITTING IDENTIFICATION HEX TYPE PLUGS STUD ENDS with 37 JIC or L series DIN MBTL opposite end MATERIAL Dash Size Thr...

Страница 274: ...87 47 60 305 321 336 415 435 456 32 21 2 12 2 50 63 50 375 394 413 510 534 560 TYPE FITTING IDENTIFICATION STUD ENDS with ORFS or S series DIN MBTS opposite end MATERIAL Dash Size Thread Size A Torque...

Страница 275: ...87 47 60 305 321 336 415 435 456 32 21 2 12 2 50 63 50 375 394 413 510 534 560 TYPE FITTING IDENTIFICATION ADJUSTABLE STUD END with 37 JIC or L series DIN MBTL opposite end MATERIAL Dash Size Thread...

Страница 276: ...87 47 60 305 321 336 415 435 456 32 21 2 12 2 50 63 50 375 394 413 510 534 560 TYPE FITTING IDENTIFICATION ADJUSTABLE STUD END with ORFS or S series DIN MBTS opposite end MATERIAL Dash Size Thread Siz...

Страница 277: ...1 87 47 60 305 321 336 415 435 456 32 21 2 12 2 50 63 50 375 394 413 510 534 560 TYPE FITTING IDENTIFICATION HOLLOW HEX PLUGS MATERIAL Dash Size Thread Size A Torque UNF in mm Min Nom Max Min Nom Max...

Страница 278: ...1 33 30 20 15 8 12 1 63 41 30 24 17 8 12 1 87 47 60 32 21 2 12 2 50 63 50 TYPE FITTING IDENTIFICATION ZERO LEAK GOLD HOLLOW HEX PLUGS MATERIAL Dash Size Thread Size A Torque UNF in mm Min Nom Max Min...

Страница 279: ...ings refer to Adjustable Stud End Assembly for proper assembly 6 Torque the fitting or nut to value listed in Table 5 18 Table 5 19 Table 5 20 Table 5 21 Table 5 22 or Table 5 23 while using the Doubl...

Страница 280: ...3 65 69 72 103 108 113 140 146 153 M27x2 22 66 70 73 90 95 99 140 147 154 190 199 209 M33x2 28 111 117 122 150 159 165 251 264 276 340 358 374 M42x2 35 177 186 195 240 252 264 369 388 406 500 526 550...

Страница 281: ...25 132 137 66 70 73 90 95 99 M27x2 22 133 140 146 180 190 198 133 139 146 180 189 198 M33x2 28 229 241 252 310 327 342 229 240 252 310 326 341 M42x2 35 332 349 365 450 473 495 332 348 365 450 473 495...

Страница 282: ...66 70 73 90 95 99 M27x2 22 96 101 106 130 137 144 236 248 260 320 336 353 100 105 110 135 142 149 M33x2 28 266 280 293 360 380 397 166 175 183 225 237 248 M42x2 35 398 418 438 540 567 594 266 280 293...

Страница 283: ...5 69 72 125 132 138 170 179 187 M27x2 20 66 70 73 89 95 99 199 209 219 270 283 297 M33x2 25 111 117 122 150 159 165 302 317 332 410 430 450 M42x2 30 177 186 195 240 252 264 398 418 438 540 567 594 M48...

Страница 284: ...37 M22x1 5 18 100 105 110 135 142 149 100 105 110 135 142 149 M27x2 22 133 140 146 180 190 198 133 140 146 180 190 198 M33x2 28 229 241 252 310 327 342 229 241 252 310 327 342 M42x2 35 332 349 365 450...

Страница 285: ...110 115 121 92 97 101 125 132 137 59 62 65 80 84 88 M22x1 5 18 89 94 98 120 127 133 100 105 110 135 142 149 M27x2 22 100 105 110 135 142 149 236 248 260 320 336 353 M33x2 28 266 280 293 360 380 397 M...

Страница 286: ...read the fitting by hand until contact 5 For Adjustable fittings refer to Adjustable Stud End Assembly for proper assembly 6 Torque the fitting or nut to value listed in Table 5 24 while using the Dou...

Страница 287: ...10x1 6 11 12 12 15 16 16 15 16 17 20 22 23 M12x1 5 8 18 19 20 25 26 27 26 28 29 35 38 39 M14x1 5 10 26 28 29 35 38 39 33 35 36 45 47 49 M16x1 5 12 30 32 33 40 43 45 41 43 45 55 58 61 M18x1 5 15 33 35...

Страница 288: ...2 22 48 51 53 65 69 72 81 86 90 110 117 122 M30x2 62 65 68 84 88 92 114 120 125 155 163 169 M33x2 25 78 82 86 106 111 117 150 157 164 203 213 222 M38x2 88 93 97 119 126 132 153 161 168 207 218 228 M42...

Страница 289: ...ngs refer to Adjustable Stud End Assembly for proper assembly 6 Torque the fitting or nut to value listed in Table 5 25 Table 5 26 Table 5 27 Table 5 28 Table 5 29 or Table 5 30 while using the Double...

Страница 290: ...95 99 133 140 146 180 190 198 G1A 28 111 117 122 150 159 165 243 255 267 330 346 362 G1 1 4A 35 177 186 195 240 252 264 398 418 438 540 567 594 G1 1 2A 42 214 225 235 290 305 319 465 489 512 630 663...

Страница 291: ...140 146 180 190 198 133 140 146 180 190 198 G1A 28 229 241 252 310 327 342 229 241 252 310 327 342 G1 1 4A 35 332 349 365 450 473 495 332 349 365 450 473 495 G1 1 2A 42 398 418 438 540 567 594 398 41...

Страница 292: ...7 230 243 254 103 108 113 140 146 153 G1A 28 236 248 260 320 336 353 148 156 163 200 212 221 G1 1 4A 35 398 418 438 540 567 594 295 313 5 332 400 425 450 G1 1 2A 42 516 542 568 700 735 770 332 349 365...

Страница 293: ...199 209 219 270 283 297 G1A 25 111 117 122 150 159 165 251 264 276 340 358 374 G1 1 4A 30 177 186 195 240 252 264 398 418 438 540 567 594 G1 1 2A 38 214 225 235 290 305 319 516 542 568 700 735 770 MA...

Страница 294: ...A 20 133 140 146 180 190 198 133 140 146 180 190 198 G1A 25 229 241 252 310 327 342 229 241 252 310 327 342 G1 1 4A 30 332 349 365 450 473 495 332 349 365 450 473 495 G1 1 2A 38 398 418 438 540 567 59...

Страница 295: ...73 90 95 99 89 94 98 120 127 133 G3 4A 20 92 97 101 125 132 137 170 179 187 230 243 254 G1A 25 236 248 260 320 336 353 G1 1 4A 30 398 418 438 540 567 594 G1 1 2A 38 516 542 568 700 735 770 MATERIAL B...

Страница 296: ...lits scratches dirt foreign matter or burrs 2 See Figure for O ring installation instructions 3 Pre lubricate the O ring with Hydraulic Oil 4 Position flange and clamp halves 5 Place lock washers on b...

Страница 297: ...110 116 111 116 122 150 158 165 40 2 50 64 3 50 88 90 1 2 13 77 81 85 105 110 116 111 116 122 150 158 165 48 3 00 76 4 19 106 43 5 8 11 155 163 170 210 221 231 218 228 239 295 310 325 56 3 50 89 4 75...

Страница 298: ...01 68 71 75 92 97 101 40 2 50 64 3 50 88 90 M12x1 75 68 71 75 92 97 101 68 71 75 92 97 101 48 3 00 76 4 19 106 43 M12x1 75 68 71 75 92 97 101 68 71 75 92 97 101 56 3 50 89 4 75 120 65 M16x2 155 163 17...

Страница 299: ...up wrench If two wrenches are not used inadvertent component rotation may occur which absorbs torque and causes improper joint load and leads to leaks For hose connections the layline printed on the...

Страница 300: ...connection has been properly tightened mark a straight line across the connecting parts not covering the dots to indicate the connection has been properly tightened Adjustable Stud End Assembly For Ad...

Страница 301: ...cks If any are found replace O ring 2 Ensure proper O ring to be installed Many O rings look the same but are of different material different hard ness or are slightly different diameters or widths 3...

Страница 302: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 50 3121619 Figure 5 15 Turntable Hydraulic System...

Страница 303: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 3121619 5 51 Figure 5 16 Hydraulic Hose Installation Sheet 1 of 8...

Страница 304: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 52 3121619 Figure 5 17 Hydraulic Hose Installation Sheet 2 of 8...

Страница 305: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 3121619 5 53 Figure 5 18 Hydraulic Hose Installation Sheet 3 of 8...

Страница 306: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 54 3121619 Figure 5 19 Hydraulic Hose Installation Sheet 4 of 8...

Страница 307: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 3121619 5 55 Figure 5 20 Hydraulic Hose Installation Sheet 5 of 8...

Страница 308: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 56 3121619 Figure 5 21 Hydraulic Hose Installation Sheet 6 of 8...

Страница 309: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 3121619 5 57 Figure 5 22 Hydraulic Hose Installation Sheet 7 of 8...

Страница 310: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 58 3121619 Figure 5 23 Hydraulic Hose Installation Sheet 8 of 8...

Страница 311: ...er barrel in a suitable holding fixture Tap around outside of cylinder head retainer with a suitable hammer to break thread locking compound 5 Mark cylinder head and barrel with center punch marks for...

Страница 312: ...ing 2 Barrel 3 CounterbalanceValve 4 Capscrew 5 WasherRing 6 WiperSeal 7 Seal 8 CylinderHead 9 BackupRing 10 O Ring 11 WearRing 12 Spacer 13 BackupRing 14 O Ring 15 Piston 16 LockRing 17 Seal 18 Taper...

Страница 313: ...reads as necessary 4 Inspect inner surface of cylinder barrel tube for scoring or other damage Check inside diameter for tapering or ovality Replace if necessary 5 Inspect threaded portion of barrel f...

Страница 314: ...film of hydraulic oil to all components before assembly 1 Install backup ring and o ring in outside diameter grooves of cylinder head 3 Install rod seal wiper ring and wear rings in cylinder head as...

Страница 315: ...aces between the capscrews b Tap each space once this means the tapered bush ing is tapped 3 times as there are 3 spaces between the capscrews 13 Retorque the capscrews evenly and progressively in rot...

Страница 316: ...m cylinder port block Discard O rings 4 Place cylinder barrel in a suitable holding fixture Tap around outside of cylinder head retainer with a suitable hammer to break thread locking compound 5 Mark...

Страница 317: ...Torque to 50 55 ft lb 67 75 Nm Torque to 30 ft lb 41 Nm 1 Bushing 2 Barrel 3 CounterbalanceValve 4 Capscrew 5 WasherRing 6 WiperSeal 7 RodSeal 8 CylinderHead 9 WearRing 10 BackupRing 11 O Ring 12 Spa...

Страница 318: ...SE A KNIFE SHARP OBJECT OR SCREW DRIVER MAKE NOTE OF SEAL ORIENTATION BEFORE REMOVING FOR PROPER INSTALLATION 12 Remove and discard backup ring 13 O ring 14 and backup ring 13 from inside grooves of p...

Страница 319: ...aded portion of head for damage Dress threads as necessary 11 Inspect seal and O ring grooves in head for burrs and sharp edges Dress applicable surfaces as necessary 12 Inspect cylinder head outside...

Страница 320: ...Do not damage or dislodge wiper and rod seals Push cylinder head to rod end 4 Install spacer 12 on rod 21 5 Install backup ring 13 O ring 14 and backup ring 13 in inside grooves of piston 15 6 Instal...

Страница 321: ...as there are 3 spaces between the capscrews 13 Re torque capscrews evenly and progressively in rota tion to 30 ft lb 41 Nm INSERTING ROD OFF CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES USE...

Страница 322: ...ove cartridge type counterbalance valve and fit tings from cylinder port block Discard O rings 5 If neccessary remove eight capscrews 8 and retainer cap 7 Remove O Ring plug 12 and setscrew 11 Remove...

Страница 323: ...e to 9 ft lb 12 Nm Torque to 200 ft lb 271 Nm 1 Screw 2 CounterbalanceValve 3 Barrel 4 Bushing 5 SpacerSleeve 6 LengthSensor 7 RetainerCap 8 Capscrew 9 RetainingRing 10 SensorMagnet 11 Setscrew 12 Plu...

Страница 324: ...iston 13 Screw piston counter clockwise by hand and remove from cylinder rod REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY DO NOT USE A KNIFE SHARP OBJECT OR SCREW DRIVER MAKE NOTE OF SEAL ORIENTATI...

Страница 325: ...damage ovality and tapering Replace as necessary 13 Inspect cylinder length sensor components for damage Replace as needed 14 Inspect rod and barrel bearings for signs of excessive wear or damage Rep...

Страница 326: ...P N 0100011 or equivalent to tapered bushing capscrews and assemble the tapered bushing loosely into the piston Insert capscrews through the drilled holes in the bushing and into the tapped holes in...

Страница 327: ...and support rod NOTE Apply locking primer and JLG Threadlocker01 P N 0100011 to cylinder head threads 16 Insert piston end into barrel cylinder Do not damage or dislodge piston loading O ring and seal...

Страница 328: ...nd fittings from cylinder port block Discard O rings 4 Place cylinder barrel in a suitable holding fixture Tap around outside of cylinder head retainer with a suitable hammer to break thread locking c...

Страница 329: ...e 3 CounterbalanceValve 4 CounterbalanceValve 5 Barrel 6 Capscrew 7 WasherRing 8 WearRing 9 BackupRing 10 O Ring 11 WiperSeal 12 RodSeal 13 Head 14 BackupRing 15 O Ring 16 BackupRing 17 Piston 18 Lock...

Страница 330: ...AND INSPECTION 1 Clean parts thoroughly with approved cleaning solvent 2 Inspect cylinder rod for scoring tapering ovality or other damage If necessary dress rod with Scotch Brite or equivalent Replac...

Страница 331: ...ubrication is not required with nickel plated pins and bearings Install pin in composite bushing dry d Press bushing into barrel or rod bushing with cor rect size arbor 14 Inspect port block fittings...

Страница 332: ...ushing loosely into the piston and insert capscrews through the drilled holes in the bushing and into the tapped holes in the piston 7 Tighten the capscrews evenly and progressively in rota tion to 60...

Страница 333: ...amp barrel 5 securely and support rod 24 Insert piston 17 end in barrel Do not damage or dislodge pis ton O rings or seal rings 13 Continue pushing rod in barrel until cylinder head 13 can be inserted...

Страница 334: ...rce Adequately support cylinder rod if applicable 3 Place cylinder barrel in a suitable holding fixture 4 Remove cartridge type counterbalance valve and fit tings from cylinder port block Discard O ri...

Страница 335: ...ue to 9 ft lb 12 Nm 1 Barrel 2 CounterbalanceValve 3 Bushing 4 Setscrew 5 O RingPlug 6 Spacer 7 SensorMagnet 8 InternalRetainingRing 9 CylinderLengthSensor 10 RetainerCap 11 Capscrew 12 Bolt 13 Tapere...

Страница 336: ...er clockwise by hand and remove from cylinder rod REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY DO NOT USE A KNIFE SHARP OBJECT OR SCREW DRIVER MAKE NOTE OF SEAL ORIENTATION BEFORE REMOVING FOR PROP...

Страница 337: ...coring damage ovality and tapering Replace as necessary 13 Inspect cylinder length sensor components for damage Replace as needed 14 Inspect rod and barrel bearings for signs of excessive wear or dama...

Страница 338: ...ll tapered bushing NOTE When installing the tapered bushing piston and mating end of rod must be free of oil 9 Apply JLG Threadlocker P N 0100011 to tapered bush ing bolts Assemble the tapered bushing...

Страница 339: ...iston loading O ring and seal ring 14 Continue pushing rod into barrel until cylinder head gland can be inserted into barrel cylinder NOTE Apply JLG Threadlocker P N 0100011 or equivalent to capscrews...

Страница 340: ...4 Mark cylinder head and barrel with a center punch for realignment Unscrew cylinder head with pin face span ner wrench PULLING ROD OFF CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES USE EXTRE...

Страница 341: ...C INFORMATION HYDRAULIC SCHEMATICS 3121619 5 89 1 8 4 3 2 6 5 7 9 11 10 1001119313 1 Rod 2 Seal 3 WearRing 4 Barrel 5 O Ring 6 BackupRing 7 O Ring 8 Head 9 WearRing 10 Seal 11 RodWiper Figure 5 91 Jib...

Страница 342: ...y and tapering Replace as necessary 11 Inspect oil ports for blockage or presence of dirt or other foreign material Repair as necessary ASSEMBLY NOTE Use proper cylinder seal kit for cylinder assembly...

Страница 343: ...d 5 and barrel 2 5 Unscrew cylinder head with pin face spanner wrench PULLING ROD OFF CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES USE EXTREME CARE WHEN REMOVING CYLINDER ROD HEAD AND PISTON...

Страница 344: ...AULIC SCHEMATICS 5 92 3121619 1001155986 1 Bushing 2 Barrel 3 WiperSeal 4 Seal 5 Head 6 O Ring 7 BackupRing 8 O Ring 9 Screw 10 WearRing 11 O Ring 12 Piston 13 Setscrew 14 WearRing 15 Seal 16 Bushing...

Страница 345: ...s threads as necessary 11 Inspect seal and O ring grooves in head for burrs and sharp edges Dress applicable surfaces as necessary 12 Inspect cylinder head outside diameter for scoring damage ovality...

Страница 346: ...fixture and support rod Insert piston end into barrel cylinder Do not dam age or dislodge piston O rings or seal rings 12 Apply ant seize compound to cylinder head threads 13 Continue pushing rod int...

Страница 347: ...ght socket head screws 6 and two pad sup ports 7 from cylinder head 12 Reinstall one socket head screw finger tight 6 Remove three cartridge valves from valve block 7 Tap around outside of cylinder he...

Страница 348: ...ft lb 27 Nm Torque to 25 30 ft lb 33 40 Nm Torque to 100 ft lb 135 Nm 1 ShuttleValve 2 CounterbalanceValve 3 Barrel 4 Bolt 5 Washer 6 WearPad 7 Capscrew 8 SupportPad 9 Washer 10 Nut 11 Wiper 12 Seal 1...

Страница 349: ...ck inside diameter for tapering or ovality Replace if necessary 4 Inspect piston surface for damage scoring or distortion Dress piston surface or replace piston as necessary 5 Inspect threaded portion...

Страница 350: ...eal 22 and two wear rings in outer grooves of piston 8 Using suitable protection clamp cylinder rod in a vise or similar holding fixture as close to piston as possible 9 Apply medium strength locking...

Страница 351: ...0 ft lb 27 Nm following sequence shown in Figure 5 107 16 Install each wear pad 5 with two bolts 3 four washers 4 and two bolts 9 17 Install shuttle valve 1 with new O ring in valve block Torque to 20...

Страница 352: ...ngs Remove four capscrews 1 and valve block from rod 7 Discard O rings 5 6 5 Mark cylinder head 23 and barrel 28 with center punch marks for later realignment Remove two cap screws 27 and bracket 26 6...

Страница 353: ...CheckCartridge 4 CounterbalanceValve 5 O Ring 6 O Ring 7 Rod 8 Bolt 9 TaperedBushing 10 Piston 11 WearRing 12 Seal 13 BackupRing 14 WasherRing 15 Capscrew 16 Spacer 17 WearRing 18 O Ring 19 Back UpRi...

Страница 354: ...OR SCREW DRIVER MAKE NOTE OF SEAL ORIENTATION BEFORE REMOVING FOR PROPER INSTALLATION 13 Remove and discard two backup rings 13 washer ring 14 two wear rings 11 and seal 12 from piston 10 14 Remove c...

Страница 355: ...sary 10 Inspect seal and O ring grooves in head for burrs and sharp edges Dress applicable surfaces as necessary 11 Inspect cylinder head outside diameter for scoring damage ovality and tapering Repla...

Страница 356: ...and mating end of rod must be free of oil when installing tapered bushing 10 Thread piston on rod until it aligns with spacer end and install tapered bushing 11 Apply JLG Threadlocker P N 0100011 to...

Страница 357: ...nd support rod Insert piston end into barrel Do not damage or dislodge pis ton O ring and seal ring 18 Push rod in barrel until cylinder head can be inserted 19 Install cylinder head 23 in barrel 28 a...

Страница 358: ...lbs 84 kg and the platform level cylinder weighs approximately 76 lbs 34 kg 2 Support the weight of the jib cylinder and remove the bolt and keeper pin that secure the cylinder barrel retaining pin R...

Страница 359: ...ULIC SCHEMATICS 3121619 5 107 7 Using an allen wrench remove the bolts securing the retaining cap and remove the cap 8 Pull sensor out of the cylinder DO NOT use the wiring harness to pull the sensor...

Страница 360: ...the sensor bore DO NOT tap on the wiring harness 2 Install the cap and secure in place with the retaining bolts 3 Apply lubricant JLG P N 3020039 to the setscrew and install the setscrew Torque the se...

Страница 361: ...lect switch to the ground controls and start the engine 3 Locate the oil sampling valve on the front of the main control valve 4 Unscrew the knurled end which is attached to the chain 5 Place a drip p...

Страница 362: ...AIN DUMP MP4 MP5 MAIN TELE OUT MAIN LIFT UP SWING RIGHT LIFT DOWN AUX LIFT PILOT SWING LEFT RELIEF LIFT UP RELIEF PORT 5 PORT 4 TELE OUT RELIEF PORT 8 PORT 7 M8 PRESSURE REDUCING VALVE REDUCED PRESSUR...

Страница 363: ...19 5 111 MP CHASSIS ENABLE WARM UP TELE CNTL M7 LIFT CNTL M4 TELE OUT RELIEF SWING CNTL LIFT DOWN RELIEF MS2 M5 SWING RIGHT RELIEF MS3 LIFT DOWN AUX LIFT PILOT SWING LEFT MAIN LIFT DOWN MAIN TELE IN M...

Страница 364: ...SCHEMATICS 5 112 3121619 Figure 5 126 Main Valve Torque Values Sheet 1 of 2 Item Ft Lbs Nm 1 60 70 81 95 2 25 30 34 40 5 3 40 49 54 66 4 2 2 3 3 4 5 30 35 40 5 47 6 122 133 165 180 7 3 7 5 2 5 7 8 28...

Страница 365: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 3121619 5 113 Figure 5 127 Main Valve Torque Values Sheet 2 of 2...

Страница 366: ...the main valve block 2 Remove the Deutsch connector from the lift down coil 3 Activate lift down The gauge should read 4000 psi 275 bar 4 To make an adjustment to this pressure go back to the engine c...

Страница 367: ...or from lift down coil 3 Turn adjustment screws on the pressure reducing valve located at 3 o clock adjacent to port P4 and the relief valve located at 5 o clock adjacent to port P4 fully clock wise E...

Страница 368: ...ten locknuts LIFT UP 1 Install a high pressure gauge at the M5 port of the main valve block 2 Plug and cap the hose on port 5 Activate lift up The gauge should read 3700 psi 255 bar 3 The adjustment c...

Страница 369: ...ld read 2850 psi 196 bar The adjustment car tridge is located to the left of the M4 gauge port Turn clockwise to increase counterclockwise to decrease SWING 1 Install a high pressure gauge at port MS2...

Страница 370: ...pres sure TELESCOPE OUT NOTE NEVER increase telescope out pressure to achieve desired telescope length 1 Install a high pressure gauge at the M8 port of the main valve bank 2 Plug the telescope out ho...

Страница 371: ...port of the main valve block 2 Plug the telescope in hose either at the valve bank port 7 or at the inlet of the telescope cylinder V2 3 Activate telescope in The gauge should read 3300 psi 227 bar Th...

Страница 372: ...AR 1 To extend the axles drive the machine back and forth until extended A machine that cannot be driven must be jacked up 2 On both the front and rear frame valve banks install a high pressure gauge...

Страница 373: ...ear valves Each relief valve is located next to its own gauge port Turn clockwise to increase counterclockwise to decrease 4 Adjustments Made at the Platform Valve Bank PLATFORM LEVEL UP 1 Install a h...

Страница 374: ...extend This is the bottom relief valve on the platform valve Turn CW to increase and CCW to decrease pressure 5 Adjustments Made at Jib Valve JIB LEVEL UP NOTE To check or adjust the jib level up pres...

Страница 375: ...zer should read JIB SWING Press ENTER 8 Enter code 58237 and Press ENTER The screen should read SERVICE MODE JIB SWING AND JIB LEVEL 9 Press ENTER again The screen will read JIB LEVEL OVERRIDE OFF Use...

Страница 376: ...r pressure is set and cycle machine power JIB LEVEL DOWN 1 Install high pressure gauge at MLA 2 Connect the analyzer to the ground control connector 3 Position the main boom on the boom rest and the j...

Страница 377: ...is will activate the Jib Level Down function 11 When the cylinder is completely retracted the pressure should be 1500 psi 104bar CW increases and CCW decreases setting Jib level down adjustment is adj...

Страница 378: ...erride to off after pressure is set and cycle machine power Operate the main boom to verify jib level is working properly JIB TELESCOPE OUT 1 Install high pressure gauge at MTB 2 Extend jib telescope...

Страница 379: ...or cap port JB 3 Set pressure to 2800 psi 193bar Clockwise increases and Counterclockwise decreases setting Adjustment is on the boom side of MJB JIB LIFT DOWN 1 Install high pressure gauge at port MJ...

Страница 380: ...Adjust the charge relief valve to obtain reading of 400psi 28bar The charge relief is located on the turntable side of the pump above M3 Clockwise increases pressure Counterclockwise decreases pressur...

Страница 381: ...Swashplate Cylinder block Swashplate bearing Swashplate bearing Front shaft bearing Center shaf t bearings Rear shaft bearin g Figure 5 128 Piston Pump Cross Sectional View Table 5 33 Port information...

Страница 382: ...1 1 5 16 12 System port B ISO 11926 1 1 5 16 12 Servo gauge port M4 ISO 11926 1 7 16 20 Charge inlet port E ISO 11926 1 1 5 16 12 Servo gauge port M5 ISO 11926 1 7 16 20 Case drain port L3 ISO 11926 1...

Страница 383: ...ge port MB ISO 11926 1 9 16 18 Brake gage port X7 ISO 11926 1 9 16 18 Charge constr port M3 ISO 11926 1 9 16 18 Se rvo gauge port M4 ISO 11926 1 7 16 20 Servo gauge port M5 ISO 11926 1 7 16 20 Case dr...

Страница 384: ...r for several seconds Do not to exceed the engine manufacturer s recommenda tion Wait 30 seconds and then crank the engine a sec ond time as stated above This operation helps remove air from the syste...

Страница 385: ...ndseeifpumpcomesbacktoneutral IfYes controlneu tralimproperlyset Ifno balanceswashplate seeMechanical neutraladjustment Ifyoustillcannotsetneutral replacecon trol Table 5 36 System operating hot Item...

Страница 386: ...ck HPRVs Inputtocontrol Inputtocontrolmoduleisoperatingimproperly Repairorreplacecontrol Optionalcontrolcutoffvalve Controlcutoffvalvecoilnotenergized EnsurechargepressuretocontrolviaportX7 If none co...

Страница 387: ...ed Chargeandcontrolpressures Incorrectpressureswillaffectsystemperfor mance Measureandadjustchargeandcontrolpres sures Airinsystem Airinsystemwillproducesluggishsystem response Filltanktoproperlevel C...

Страница 388: ...valve set tings refer to model code located on serial number plate These pressures assume 1800 min 1 rpm pump speed and a reservoir temperature of 50 C 120 F and are referenced to case pressure NOTE L...

Страница 389: ...turn adjusting screw to reduce any pressure differential NOTE Adjustment of the EDC is very sensitive Be sure to hold the hex wrench steady while loosening the locknut Total adjustment is less than 12...

Страница 390: ...for both the front and rear sections Alternate M4 M5 and MA MB to zero out forward and reverse directions of the front unit then move the gauges to M4 M5 of the rear unit and MC MD system gauge ports...

Страница 391: ...ear servo gauge port M5 ISO 11926 1 7 16 20 System port MD ISO 11926 1 9 16 18 System gauge port MA ISO 11926 1 9 16 18 System gauge port MC ISO 11926 1 9 16 18 System gauge port MB ISO 11926 1 9 16 1...

Страница 392: ...1 6 on the rear pump Remember that the rear pump is a mirror image of the front pump and therefore the locations of the servo gauge ports M4 M5 and the control sole noids C1 C2 are opposite 13 Remove...

Страница 393: ...ed in the center of the con trol module when installing control REASSEMBLY NOTE Ensure you install dowel pins D300 in housing before installing control 1 Install a new gasket D150 2 If you removed scr...

Страница 394: ...onnect electrical connections and test the pump for proper operation Shaft Seal and Bearing The front pump input shaft assembly is serviceable without disassembling the pump the rear shaft is not Orie...

Страница 395: ...tion pump with front shaft pointing downward Attach securely to a proper work stand If an auxiliary pump is attached remove auxiliary pump before servicing charge pump REMOVAL 1 Remove screws K351 and...

Страница 396: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 144 3121619 Figure 5 136 Charge Pump...

Страница 397: ...g in the table Charge Check HPRV The high pressure relief and charge check valve assembly may be removed for cleaning and replacement of the O rings These valves are factory set and are not field adju...

Страница 398: ...or a 1 in V10 2 wrench remove the charge pressure relief valve Discard the O rings V10A INSPECTION 1 Inspect the sealing surfaces of the pump and charge pressure relief valve for nicks or scratches r...

Страница 399: ...wrench to remove the control cutoff valve G10 Remove and discard the O rings and backup rings G10A INSPECTION 1 Inspect the sealing surfaces of the pump and control cutoff valve for nicks or scratche...

Страница 400: ...3Nm 9 5lbft E350 Servocylinderlockingscrew 10mmhex 14 5Nm 11lbft G10 Controlcutoffvalve 11 16inhex 45Nm 33lbft G10B Controlcutoffvalvecoilnut 24mmhex 9Nm 7lbft K007 Chargecheck HPRV 8mminternalhex 80N...

Страница 401: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 3121619 5 149 Figure 5 141 Fastener and Plug Locations...

Страница 402: ...6 Remove the bearing cup B010 bearing cone B020 and housing O ring K060 Discard the O ring 7 Tilt the housing on its side to allow fluid to drain 8 Remove the cylinder block kit while holding onto th...

Страница 403: ...ly pry out the shaft seal K020 If you are unable to pull the shaft seal out try to push the seal out by going through the inside of the housing 21 Remove the 4 plugs C103 C104 C105 C106 and their O ri...

Страница 404: ...n solvent and allow to air dry Blow out oil passages in the housing and endcap with com pressed air Conduct inspection in a clean area and keep all parts free from contamination Clean and dry parts ag...

Страница 405: ...ar and replace if necessary Check the spool s outside diameter for scratches and or burrs Clean and coat all spools bores and seals with a light coating of hydraulic oil INPUT SHAFT Check to see that...

Страница 406: ...s these may decrease pump flow Lap or replace if grooves or nicks are present Inspect the mating sur faces of the endcap and valve plate for any possible contami nation even a few thousandths of an in...

Страница 407: ...a solvent and lubricate with hydraulic fluid NOTE Replace the bearing if the problem is not remedied by cleaning Inspect for uneven wear If abnormal wear is found replace the bearing kit Assembly 1 Co...

Страница 408: ...ock 8 Install the pistons K050 to the slipper retainer K049 Install the piston retainer assembly into the cylinder block Ensure the concave surface of the retainer seats on the ball guide If you re re...

Страница 409: ...he housing just far enough to clear the retaining ring groove Install seal with the cupped side toward the shaft bearing Do not damage the seal dur ing installation Using the appropriate snap ring pli...

Страница 410: ...housing Install and tighten set screw C102 at 7 5 to 10 8 Nm 5 5 to 8 0 lbft Also install the plugs C105 C106 with new O rings Torque the plugs at 10 8 to 13 5 Nm 8 to 10 lbft NOTE PC and LS spools n...

Страница 411: ...y bearings gears and body faces Do not touch or score them with metal tools or cutting edges MARKING THE PARTS Mark the parts before completely disassembling a pump The marks allow components to be re...

Страница 412: ...onding screws on the rear flange 4 Remove front flange Place the pump on the table and slowly remove the front flange Be careful not to damage the shaft seal when removing the flange Avoid contact of...

Страница 413: ...henever there are burrs evidence of extrusion or marks caused by overheating If the seals need to be replaced carefully remove them from the flange cover beginning with the backup ring and then the pr...

Страница 414: ...he seals Have the entire seal kit available Lightly coat all seals with seal grease The grease is needed to adhere the seals to their grooves Do not install dry seals 2 Install shaft seal into front f...

Страница 415: ...on backup ring Ensure that the seals are located in the grooves as shown 5 Prepare the body Clean the body Inspect the internal and mating surfaces Ensure the sur faces are free of burrs and scratches...

Страница 416: ...and bottom of the gears Ensure these surfaces are free from burrs or scratches If scratches or burrs are found clean them with a flat stone and or very fine emery paper Rewash the gears after this ope...

Страница 417: ...using as before dis assembly Ensure that the relative position of the gear mesh is maintained as before disassembly Misalign ment of the gear teeth may increase operating noise 10 Install the gear blo...

Страница 418: ...may drop inside the pump during assem bly 13 Clean the mating surfaces Remove any excess lubrication and grease from the mat ing surfaces of the front flange and rear cover Ensure that these surfaces...

Страница 419: ...by the shaft splines keyway during front flange assembly Install the flange onto the body then remove the pro tective sleeve Ensure that the seals remain seated in their grooves dur ing this operation...

Страница 420: ...to flange pilot 19 Testing After pump has been disassembled and reassembled it is suggested that the pump be run in and tested on an appropriate test stand This is done to verify the volu metric effi...

Страница 421: ...tem Description Action 1 Checkoillevelinreservoir Excessiveairwillcausecavitationsound Fillreservoirtoproperlevel 2 Checkinletlineforleaks Excessiveairwillcausecavitationsound Repairinletline 3 Checkp...

Страница 422: ...he machine is accomplished by a flow divider combiner car tridge installed in the Traction Control Manifold There is a flow divider combiner for each side Each flow divider combiner also has a bleed o...

Страница 423: ...cated on the Traction Manifold This disables the machine s ability to release the brakes Stroke the transmission pumps slightly less than 20 and check the setting of the high pressure cross port relie...

Страница 424: ...BORE 5 5 IN ROD 4 5 IN STROKE 333 15 BORE 8 0 IN ROD 7 0 IN STROKE 84 9 B10 1000 43 PSI 3BAR BYPASS P1 P2 LS T3 T1 8 EXH MAIN DUMP 4000PSI 275 9BAR 500PSI 34 5BAR 2800PSI 193BAR 5A 4 5 7 9BAR 1 03BAR...

Страница 425: ...T 2 P TO JIB VALVE SWING BRAKES B10 1000 43 PSI 3BAR BYPASS P4 2 2A 3 3A SWING SWING 2000PSI 138BAR 245 BAR 2000PSI 138BAR P T A B b a A B A B MS2 MS3 SWING DRIVES MP4 MP5 MAIN CONTROL VALVE SWING FLO...

Страница 426: ...16 49 SQ IN STROKE 14 24 IN STEERING CYLINDERS BORE 4 75 IN 17 72 SQ IN ROD 1 75 IN 2 4 SQ IN ANNULAR 15 32 SQ IN STROKE 9 8 IN LEFT VALVE MS2 MS1 MS4 MS3 A 3 A 1 S 1 S 3 S 4 P T S 2 MA1 p t a b a p...

Страница 427: ...1 V 2 V 1 SWIVEL PORT 2 RIGHT VALVE M A 2 P T M A 1 A 3 A 1 A 2 S 1 M S 1 M S 2 S 2 S 3 M S 3 M S 4 S 4 a p t b b p t a b p t a 2 0 0 0 p s i 2 6 0 0 p s i 2 0 0 0 p s i 2 6 0 0 p s i 2 5 0 0 p s i 2...

Страница 428: ...VALVE PAGE 1 TO PORT T4 MAIN CONTROL VALVE PAGE 1 SWIVEL PORTS D MP 300 PSI 20 7 BAR TRACTION MANIFOLD BRAKE 2 SPEED A3 B3 A5 B1 D C A B 8 7 6 5 5 6 7 8 C1 F00A F00B CW M3 MB MC PORT 7 PORT 6 PORT 5 R...

Страница 429: ...001149709 D A B C D 1 2 3 4 CW L3 FCOA FCOB C2 C1 M14 CHARGE PUMP 1 025 IN3 CHARGE PUMP FILTER B6 200 BYPASS 50PSI REAR DRIVE PUMP OIL COOLER OPTION PORT L3 OF THE PUMP TO THE INLET OF THE COOLER COOL...

Страница 430: ...8 2 8 B A R 1 9 3 1 B A R V 1 JIB LIFT CYLINDER BORE 5 ROD 2 5 STROKE 25 15 V 2 JIB TELESCOPE CYLINDER BORE 2 5 ROD 1 5 STROKE 84 06 D C A B 8 7 6 5 5 6 7 8 V 1 V 2 P 1 P 2 T 1 T 2 T 3 M L A L A 1 5 0...

Страница 431: ...V 1 T PLATFORM LEVEL CYLINDER BORE 3 55 ROD 1 5 STROKE 14 79 M L 2 0 2 G P M R 1 4 3 2 2 3 4 S 2 V 2 JIB LOCK CYLINDER BORE 2 5 ROD 1 75 STROKE 13 375 PLATFORM ROTATOR SPRING 3000 PSI P A G E 4 J I B...

Страница 432: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 180 3121619 NOTES...

Страница 433: ...ing func tions The main lift swing and drive are controlled by individual joy sticks with steering being controlled by a rocker switch built into the top the drive joystick To activate Drive Lift and...

Страница 434: ...connected backwards 2 Power up the Control System by turning the lower key to the platform or ground position and pulling both emer gency stop buttons on Using the Analyzer With the machine power on a...

Страница 435: ...TARTUP 2 1 indicates a power up When a top level menu is selected a new set of menu items may be offered for example DRIVE BOOM SYSTEM DATALOG VERSIONS Pressing ENTER with any of the above displayed m...

Страница 436: ...e above steps if the correct access level is not dis played or you can not adjust the personality settings Adjusting Parameters Using the Hand Held Analyzer Once you have gained access to level 1 and...

Страница 437: ...l 1 which will permit you to change all machine personality settings There is a setting that JLG strongly recommends that you do not change This setting is so noted below ELEVATION CUTBACK CHANGING TH...

Страница 438: ...e the splash screen will show for 3 sec onds and then launch the Diagnostics Screen The indicator lamp will light when there is an active DTC in the Fault Log The Diagnostic Screen will show active an...

Страница 439: ...SECTION 6 JLG CONTROL SYSTEM 3121619 6 7 h Figure 6 5 Ground Control Console Display Gauge INDICATORLAMP ENGINEHOURS FUELLEVEL NAVIGATEFORWARDARROW NAVIGATIONBUTTONS NAVIGATEBACKARROW...

Страница 440: ...LEVATED TILTED ELEV ELEVATION ENG ENGINE EXT EXTEND F FRONT FL FLOW FNT FRONT FOR FORWARD FWD FORWARD FSW FOOTSWITCH FUNC FUNCTION G GROUND GND GROUND GRN GREEN GM GROUNDMODULE H HOURS HW HARDWARE HWF...

Страница 441: ...ER SPD SPEED STOW STOWED STOWD STOWED SW SWITCHorSOFTWARE TELE TELESCOPE TEMP TEMPERATURE TORQ TORQUE TRN TRANSPORT T T TURNTABLE T TOWER TURNTBL TURNTABLE TWR TOWER U UPPERorUP V VOLT VER VERSION VLV...

Страница 442: ...ault The items marked in BOLD bold text on this sheet represent a new board that has never been configured MODELNUMBER 1 0 1 2 NoModel 1500SJ 1850SJ 0 ENVELOPEHEIGHT 2 0 1 1500SJ 150 MAX 1850SJ 185 MA...

Страница 443: ...degreesandaboveelevation alsocutsoutdrive 4DEGREES DRVCUT Reducesthemaximumspeedofallboomfunctionstocreepwhentiltedmore than4degreesandaboveelevation alsocutsoutdrive 3DEGREES DRVCUT Reducesthemaximum...

Страница 444: ...SKYGUARD Skyguardonlyinstalled BOTH CUTOUT SofttouchandSkyguardinstalled 0 GENSET WELDER 14 0 1 2 NO Nogeneratorinstalled BELTDRIVE Beltdrivensetup HYDRAULICDRIVE Hydraulicdrivensetup 1 GENSETCUTOUT 1...

Страница 445: ...oveelevation DRIVECUTE T Drivecutoutaboveelevationandtilted 0 Onlyvisibleundercertainmarketselections Certainmarketselectionswilllimitfunctioncutoutoptionsoralterdefaultsetting GROUNDALARM 19 0 1 2 3...

Страница 446: ...ON 25 0 1 OFFFORCREEP 20FPSFORCREEP 0 LANGUAGE 26 0 1 2 3 4 5 6 7 8 9 10 ENGLISH SPANISH EUROPORTUGUESE BRAZILIANPORTUGUESE FRENCH GERMAN DUTCH ITALIAN SIMPLIFIEDCHINESE JAPANESE KOREAN 0 LANGUAGE 27...

Страница 447: ...2 4WheelSteer 0 0 0 0 0 0 1 1 1 1 1 1 DriveType 0 0 0 0 0 0 1 1 1 1 1 1 SoftTouch Skyguard 0 0 0 0 0 0 1 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 GenSet Welder 0 0 0 0 0 0 1 1 1 1 1 1 2 2 2 2 2 2 GenSetCutou...

Страница 448: ...10 10 10 10 10 PlatformCutout 0 0 0 0 0 0 1 1 1 1 1 1 TempCutout X 0 X 0 X X X 1 X 1 X X BOLDTEXTindicatesthedefaultsetting Plaintextindicatesanotheravailableselec tion ITALICTEXTindicatesthedefaultw...

Страница 449: ...Displays adjustsmaximumreversedrivespeed 0to100 100 ELEV MAXXX Displays adjustsmaximumdrivespeed NOTE usedwhenelevationcutoutswitchesare limitingmaximumspeed 0to50 25 110 112 seeorientation CREEPMAXXX...

Страница 450: ...1 MININXX Displays adjustsminimummaintelescopein speed SameasCreepspeed 0to65 15 MAXINXXX Displays adjustsmaximummaintelescopein speed 0to100 65 45 65 seeorientation MINOUTXX Displays adjustsminimumm...

Страница 451: ...ximumjibdownspeed 0to100 76 65 100 JIBSWING ACCELX Xs Displays adjustsjibswingacceleration 0 1to5 0sec 1 5 DECELX Xs Displays adjustsjibswingdeceleration 0 1to3 0sec 0 5 MINLEFTXX Displays adjustsmini...

Страница 452: ...ys adjustsfixedswingspeed 0to100 60 PLATFORMLVLXXX Displays adjustsfixedbasketlevelspeed 0to100 75 PLATFORMROTXXX Displays adjustsfixedbasketrotatespeed 0to100 75 MAINTELEXXX Displays adjustsfixedmain...

Страница 453: ...horizontal 500 lb capacity selected DRIVE FORWARD Max high speed low torque setting drive 200 ft front wheels to front wheels Timed after machine has obtained maximum speed DRIVE REVERSE Max high spee...

Страница 454: ...e stored into the ground module i e Personalities or Calibrations Interlocks Any device that sends an electrical input For an example a limit switch proximity switch etc Platform Level The GROUND MODU...

Страница 455: ...Can Lo SN129 Load Pin MS158 1 MS15 8 2 MS158 3 A B C Shield GRN Can Lo YELCan High B A C B A C MS261 1 MS26 2 3 A B C Shi eld GRN C an Lo YEL Ca n Hig h 3 4 5 SN260 Jib Lift Cylinder Angle Sensor 1 2...

Страница 456: ...MS999 3 TeeConnector under drive pumps MS999 2 Shield GRN Can Lo YEL Can High A B C MS1001 2 A B C MS1001 1 A B C 120 OHM MS1001 3 Deutz ECM J1 Connector 54 76 Tee Connector underDeutz ECM 1 2 3 G H...

Страница 457: ...ion Instructions Calibration Procedure ReasonsforRe calibration SteeringCalibration Groundmodulereplacement Chassismodulereplacement Steersensorremovalorreplacement Persistentwheelmisalignment DriveCa...

Страница 458: ...r See Figure 6 10 See Figure 6 11 See Figure 6 12 See Figure 6 14 or See Figure 6 15 or See Figure 6 16 or See Figure 6 17 NOTE The layout shown includes all possible analyzer screens Please note that...

Страница 459: ...9 6 27 Figure 6 9 Analyzer Flow Chart Personalities Sheet 1 of 2 Software Version 7 X NOTE The layout shown includes all possible analyzer screens Please note that some screens may not be available de...

Страница 460: ...121619 Figure 6 10 Analyzer Flow Chart Personalities Sheet 2 of 2 Software Version 7 X NOTE The layout shown includes all possible analyzer screens Please note that some screens may not be available d...

Страница 461: ...3121619 6 29 Figure 6 11 Analyzer Flow Chart Machine Setup Software Version 7 X NOTE The layout shown includes all possible ana lyzer screens Please note that some screens may not be available dependi...

Страница 462: ...6 30 3121619 Figure 6 12 Analyzer Flow Chart Calibrations Software Version 7 X NOTE The layout shown includes all possible analyzer screens Please note that some screens may not be available dependin...

Страница 463: ...3121619 6 31 Figure 6 13 Analyzer Flow Chart Service Mode Software Version 7 X NOTE The layout shown includes all possible analyzer screens Please note that some screens may not be available dependin...

Страница 464: ...SECTION 6 JLG CONTROL SYSTEM 6 32 3121619 Figure 6 14 Analyzer Flow Chart Diagnostics Software Version 7 X Sheet 1 of 4...

Страница 465: ...19 6 33 Figure 6 15 Analyzer Flow Chart Diagnostics Software Version 7 X Sheet 2 of 4 NOTE The layout shown includes all possible analyzer screens Please note that some screens may not be available de...

Страница 466: ...121619 Figure 6 16 Analyzer Flow Chart Diagnostics Software Version 7 X Sheet 3 of 4 NOTE The layout shown includes all possible analyzer screens Please note that some screens may not be available dep...

Страница 467: ...19 6 35 Figure 6 17 Analyzer Flow Chart Diagnostics Software Version 7 X Sheet 4 of 4 NOTE The layout shown includes all possible analyzer screens Please note that some screens may not be available de...

Страница 468: ...5 BASKET LEVEL UP OVERRIDE DIGITAL OUTPUT 6 GROUND GROUND INPUT 7 BASKET LEVEL DOWN OVERRIDE DIGITAL OUTPUT 8 TOWER TELESCOPE POWER DIGITAL OUTPUT 9 TELESCOPE FLOW CONTROL DIGITAL OUTPUT 10 LIFT PILO...

Страница 469: ...GROUND INPUT 19 SPARE PIN GROUND INPUT 20 SPARE ANALOG INPUT 1 ANALOG INPUT 21 PUSH TO TEST DIGITAL INPUT 22 TOWER BOOM TRANSPORT ANGLE DIGITAL INPUT 23 GROUND CONTROL ENABLE DIGITAL INPUT 24 CAN LO...

Страница 470: ...EVEL UP DIGITAL INPUT 18 BASKET ROTATE RIGHT DIGITAL INPUT 19 JIB UP DIGITAL INPUT 20 JIB RIGHT DIGITAL INPUT 21 TOWER DOWN DIGITAL INPUT 22 MAIN BOOM TRANSPORT ANGLE CLOSED DIGITAL INPUT 23 UPPER LIF...

Страница 471: ...r Feed Thru to J1 2 Ground Front Axles Limit Switch Rear Axles Limit Switch Drive Orientation Switch Oscillating Axle Pres Sw Turntable Angle Sensor 1 Turntable Angle Sensor 2 Spare Analog Front Rear...

Страница 472: ...8 Main Boom Ang 1 Gravity Digital Input 9 Main Boom Ang 2 Gravity Digital Input 10 Spare Analog Analog Input 11 Right Drive Pump Forward Digital Output 12 Right Drive Pump Reverse Digital Output Conn...

Страница 473: ...ster Ground Connect Power Input 5 Master Ignition Connect Power Input 6 CANbus High Serial I O 7 CANbus Low Serial I O 8 CANbus Shield Serial I O 9 CANbus Terminator Serial I O 10 CANbus Terminator Se...

Страница 474: ...SECTION 6 JLG CONTROL SYSTEM 6 42 3121619 Figure 6 24 Analyzer Connecting Points PLATFORMCONNECTION GROUNDCONTROLCONNECTION...

Страница 475: ...ble with a load cell pin This pin is fixed to the Turntable so as to allow mea surement of the force exerted by the cylinder regardless of the cylinder orientation Sensor 2 Main Boom Angle Sensors 2 S...

Страница 476: ...IN DESC SENSOR HARNESS PIN 1 POWER RED RED PIN 2 OUTPUT WHITE BLUE PIN 3 GROUND BLACK BLACK ANGLE SENSOR 2 LEFT PIN DESC SENSOR HARNESS PIN 1 POWER RED ORANGE PIN 2 OUTPUT WHITE YELLOW PIN 3 GROUND BL...

Страница 477: ...al body with electrically opposing signals Sensor 5 Main Boom Transport Length Switch 1 See See Figure 6 27 This switch is used to indicate Main Boom retracted position for transport This is a mechani...

Страница 478: ...LIMIT SWITCH WIRING TORQUE BOLT TO 55 NM SECTION E E LIMIT SWITCH ADJUSTMENT TOP OF SENSOR LIMIT SWITCH COVER LIMIT SWITCH LIMIT SWITCH CABLE T orque 25ft lbs 34 Nm BOLT WASHER THREADLOCKER P N 010001...

Страница 479: ...the sensor arm 3 Install the sensor subassembly onto the boom 4 Connect the sensor wiring Sensor 7 Jib Lock Pin Proximity Sensor 1 This sensor is used to indicate the Jib Lock Pin is fully engaged Thi...

Страница 480: ...L BETWEEN LINKAND ARM TORQUEUNTIL SNUG 5 NM MAX BOLT SPACER ANGLE SENSOR ANGLE SENSOR SENSOR MOUNT SENSOR LINK SENSOR COVER WASHER NUT SCREW NUT SCREW THREADLOCKER P N 0100011 BOLT WASHER THREADLOCKER...

Страница 481: ...with elec trically opposing signals Sensor 9 Jib Lift Angle Sensor 1 This sensor s function is to measure the Jib angle relative to the Main Boom Pivot weldment A linear position sensor is located ins...

Страница 482: ...posing signals ADJUSTMENT Adjust the Proximity Sensors so the front sensing face is flush to 0 75 mm below the surface of the mounting face Sensor 11 Platform Level Angle Sensor 1 This sensor is used...

Страница 483: ...measures the tilted angle of the turntable relative to gravity It is mounted on a bracket on the left side of the turntable adjacent to the UGM and BLAM module It is a dual axis output sensor in a si...

Страница 484: ...Platform Ground select switch to the Plat form position 2 Pull out the Emergency Stop switch at the Ground Con trol Station 3 Plug the analyzer into the connector at the base of the platform control...

Страница 485: ...gain to activate 8 Follow the flow path in Figure 6 33 System Test Flow Chart Platform Tests Sheet 1 of 2 and Figure 6 34 Sys tem Test Flow Chart Platform Tests Sheet 2 of 2 and go through the compone...

Страница 486: ...SECTION 6 JLG CONTROL SYSTEM 6 54 3121619 Figure 6 33 System Test Flow Chart Platform Tests Sheet 1 of 2...

Страница 487: ...SECTION 6 JLG CONTROL SYSTEM 3121619 6 55 Figure 6 34 System Test Flow Chart Platform Tests Sheet 2 of 2...

Страница 488: ...to reach SYSTEM TEST Hit Enter The analyzer will prompt you asking if you want to acti vate the system test hit Enter again to activate 6 Follow the flow path in Figure 6 35 System Test Flow Chart Gr...

Страница 489: ...SECTION 6 JLG CONTROL SYSTEM 3121619 6 57 Figure 6 35 System Test Flow Chart Ground Station Tests...

Страница 490: ...itsEEPROMstoredpersonalitysettingsatswitchon Checkand ifnecessarycorrect allpersonalitysettings OPENFSW Inplatformmode thefootswitchmustbeopenatthestartofthetest CLOSEFSW Inplatformmode thefootswitchm...

Страница 491: ...witch wiring CHECKXXXXXXXJOY Thenamedjoystickappearstobefaulty Checkjoystick TESTINGLAMPS Indicatesthatthelampstestisbeginning Eachlampisenergizedinturn apromptasksforcon firmationthatthelampislit ENT...

Страница 492: ...tsdisplayedduringtheoperatorinputtestbelowmessages CLOSEXXXXXXX Thenamedswitchshouldbeclosed OPENXXXXXXX Thenamedswitchshouldbeopened XXXXXXXXXXXXXXTOMAX Thenamedjoystickshouldbepushedtoitsfullextenti...

Страница 493: ...m is clean Ensure the jib is horizontal Ensure the jib swing is centered if Jib swing is configured Ensure the platform is level Ensure the platform is not rotated Ensure the turntable is centered bet...

Страница 494: ...otate func tions and display CAL POSITION 2 on the first line 6 The controller shall display LIFT UP TO STOP After the operator presses the ENTER key the controller shall dis play CAL POSITION 3 and S...

Страница 495: ...is cycled While the boom is in this state the telescope functions will be allowed to extend or retract the boom 1 0 at a time This can be repeated until the length reading deviates from the expected w...

Страница 496: ...e performed on an individual basis 1 Position the Platform Ground select switch to the Ground position 2 Plug the analyzer into the connector inside the Ground control box 3 Pull out the Emergency Sto...

Страница 497: ...e the arrow keys to reach the JIB SENSORS The screen should read 9 Press ENTER The screen should read 10 Press ENTER The screen should read as shown below When it does activate boom lift until the con...

Страница 498: ...ed jib sensor calibration The available sensor calibrations are JIB LIFT JIB LEVEL JIB SWING PLATFORM LEVEL 12 If the operator presses enter at the jib lift sensor calibra tion prompt the screen shown...

Страница 499: ...SC will take the system back to the initial jib lift calibration display NOTE At this point the left or right arrow key may be used to skip to any of the other jib sensor calibrations 16 Hitting the E...

Страница 500: ...s at the mechanical stop the operator must hit ENTER again The screen will show 19 When the system completes this step the next screen will show 20 Press ENTER The screen should read 21 Operate jib li...

Страница 501: ...low The control system will jib level down and stop the jib leveling command 24 When the system completes the previous step the screen will read 25 Hitting the escape key ESC will take the system back...

Страница 502: ...alibration The screen will show 27 Press Enter The screen shown below will be displayed At this point use the platform rotate right function switch to swing the jib right 28 When the jib reaches the m...

Страница 503: ...o swing the jib left 31 When the jib is at the mechanical stop press ENTER The screen will show 32 At the finish of the jib swing lift calibration the jib lock pin will be locked by the control system...

Страница 504: ...ER key at this point will continue the cali bration sequence The screen will show 36 Press Enter The screen shown below will be displayed At this point use the platform level up function switch to lev...

Страница 505: ...trol system will stop the platform level and the screen will show 41 Pressing ENTER will take you back to the beginning and escape ESC will take you to the initial screen Calibrating the Jib Level Up...

Страница 506: ...again 10 You will hear engine go to 1800 rpm 11 Using UP ARROW increase the value until you see the jib level movement 12 Hit ENTER again CAL COMPLETE message should appear 13 Engine should again retu...

Страница 507: ...rt and the analyzer will display ENVLP VIOLATION 1 Using the analyzer enter access level 1 Unlock Boom can be found under the Calibrations menu 2 Once the operator selects the UNLOCK BOOM option the s...

Страница 508: ...e in and out functionality will be restored The ana lyzer menu will display Engage Tele Out until the control system cuts it out The system will cut out at 60 0 After the machine reaches the set point...

Страница 509: ...een will remain until the boom check has com pleted the check fails or the routine is interrupted by an attempted command If the check is interrupted the analyzer will display CHECK FAILED PRESS ENTER...

Страница 510: ...menu will advance If the machine does not move or moves in the wrong direction the menu CHECK FAILED WRONG TELE DIR will be displayed and the test will end The WRONG TELE RESPONSE fault will still be...

Страница 511: ...THE ANALYZER TO THE CONNECTION PORT IN THE PLAT FORM DO NOT CONDUCT ANY CRACKPOINT SETTINGS FROM THE PLATFORM NOTE Cycle the boom functions 8 to 10 times 5 seconds in each direction prior to setting...

Страница 512: ...ENTER 5 Scroll to LEVEL UP CRKPT and press ENTER 6 Press ENTER to calibrate Platform Level Up crack point NOTE Have an assistant help verify that movement occurs 7 Using the analyzer press and hold th...

Страница 513: ...o return to the calibrations menu 9 Scroll to LEVEL DOWN CRKPT and press ENTER 10 Press ENTER to calibrate Platform Level Down crackpoint NOTE Have an assistant help verify that movement occurs 11 Usi...

Страница 514: ...C to exit calibra tions 14 Push in Power Emergency stop switch to save the cali bration changes Jib Level Up and Down Crackpoints NOTE To set crackpoints for the Jib Level Up and Down a JLG analyzer i...

Страница 515: ...s ENTER 5 Scroll to JIB LVL UP CRKPT and press ENTER 6 Press ENTER to calibrate Jib Level Up crackpoint NOTE Have an assistant help verify that movement occurs 7 Using the analyzer press and hold the...

Страница 516: ...return to the calibrations menu 9 Scroll to JIB LVL DN CRKPT and press ENTER 10 Press ENTER to calibrate Jib Level Down crack point NOTE Have an assistant help verify that movement occurs 11 Using th...

Страница 517: ...exit calibrations 14 Push in Power Emergency Stop switch to save the calibration changes Main Lift Up and Down Crackpoints NOTE To set crackpoints for the Main Lift Up and Down a JLG analyzer is need...

Страница 518: ...SECTION 6 JLG CONTROL SYSTEM 6 86 3121619 4 Scroll to MENU CALIBRATIONS and press ENTER 5 Scroll to MAIN LIFT CRKPT and press ENTER 6 Press ENTER 7 Press ENTER to calibrate Main Lift Up crackpoint...

Страница 519: ...ement occurs 8 At the Ground Controls press and hold the Lift Up toggle switch until the function starts moving then press ENTER Release the Lift Up toggle switch 9 This completes the Main Lift Up cra...

Страница 520: ...occurs 11 At the Ground Controls press and hold the Lift Down toggle switch until the function starts moving then press ENTER Release the Lift Down toggle switch 12 This completes the Main Lift Down...

Страница 521: ...dle speed lift should not be moving then press ENTER Release the Lift Up tog gle switch 15 At the Ground Controls press and hold the Lift Down toggle switch until the function starts moving then press...

Страница 522: ...NG THE MAIN TELESCOPE OUT AND IN CRACKPOINT PROCEDURE NOTE To set crackpoints for the Main Telescope Out and In a JLG analyzer is needed Have an assistant on hand to help ver ify that movement occurs...

Страница 523: ...SECTION 6 JLG CONTROL SYSTEM 3121619 6 91 5 Scroll to MAIN TELE CRKPT and press ENTER 6 Press ENTER 7 Press ENTER to calibrate Main Telescope Out crackpoint...

Страница 524: ...s 8 At the Ground Controls press and hold the Telescope Out toggle switch until the func tion starts moving then press ENTER Release the Telescope Out toggle switch 9 This completes the Main Telescope...

Страница 525: ...ls press and hold the Telescope In toggle switch until the func tion starts moving then press ENTER Release the Telescope In toggle switch 12 The crackpoint setting procedure for Main Telescope Out an...

Страница 526: ...ent is permitted by a Removing the excess platform load until actual plat form load is less than Rated Load b Operation of the overriding emergency system Auxiliary Power Unit c By an authorized perso...

Страница 527: ...SECTION 6 JLG CONTROL SYSTEM 3121619 6 95 Figure 6 36 LSS Installation Sheet 1 of 4...

Страница 528: ...SECTION 6 JLG CONTROL SYSTEM 6 96 3121619 Figure 6 37 LSS Installation Sheet 2 of 4...

Страница 529: ...SECTION 6 JLG CONTROL SYSTEM 3121619 6 97 Figure 6 38 LSS Installation Sheet 3 of 4...

Страница 530: ...SECTION 6 JLG CONTROL SYSTEM 6 98 3121619 Figure 6 39 LSS Installation Sheet 4 of 4...

Страница 531: ...7 Diagnostic Menu Descriptions Diagnostics Menu Displayed on Analyzer 1st Line Parameter Displayed on Analyzer 2nd Line Parameter Value Displayed on Analyzer 2nd Line Description PLATFORMLOAD STATE OK...

Страница 532: ...roximately level for calibra tion Level the platform from ground control if neces sary to within 5 4 To access the Calibration Menu use the LEFT and RIGHT Arrow keys to select CALIBRATION from the Top...

Страница 533: ...Accessory Weights Use the up and down analyzer keys to enter the accessory weight s in lbs When all the accessory weights are entered press ENTER The screen will read LOAD SENSI NG accessory xxxlbs T...

Страница 534: ...than 575 lbs 261 kg If the platform weight is not within the allowed range the calibration attempt will be unsuccessful and the Analyzer will show the following 10 Press ENTER The control system will...

Страница 535: ...y Reduc tions and Table 6 10 Pipe Rack Capacity Reductions Table 6 9 SkyGlazier Capacity Reductions Capacity PLATFORM OVRLD PLATFORM OVRLD RESTRICT 500lb 227kg 400lb 181kg n a 550lb 250kg 400lb 181kg...

Страница 536: ...SECTION 6 JLG CONTROL SYSTEM 6 104 3121619 14 Press ENTER If calibration is successful the screen will read...

Страница 537: ...load Visual Warning at the Ground Controls should flash and the Audible Warning at Platform and Ground should sound for 5 seconds On 2 seconds Off However the controls should remain functional when us...

Страница 538: ...theywillleaveconductiveresidue Moistureshouldbeallowedtoevaporateor acceleratedwithaheat gun uselowheatandbecarefullytonotmeltconnectormaterials Moistureintrusionintothemoldedportionof theconnector ca...

Страница 539: ...console NOTE If performing the procedure from the platform console the Emergency Stop switch on the ground console must also be pulled out 4 Pull out the Emergency Stop switch 5 The analyzer screen sh...

Страница 540: ...CONTROL SYSTEM 6 108 3121619 12 Press Enter The screen will read 13 Press Enter The JLG Control System will reset an active 873 DTC and the MSSO System will be reset Press Escape to return to the CALI...

Страница 541: ...ate normally Cycling the EMS will clear the fault and allow the operator to operate the machine as a new level set point is taken VALVE DRIVER ERRORS There are three possible level valve driver errors...

Страница 542: ...e Lift swing drive and telescope will continue to operate In each of the cases above it will be necessary to re cycle the EMS to clear the fault Operable functions shall be in the creep mode except wh...

Страница 543: ...EINITIALIZED 0 0 21 RUNNINGATCREEP PLATFORMSTOWED 0 0 30 FUELLEVELLOW ENGINESHUTDOWN 0 0 31 APUACTIVE 0 0 35 JIBUNLOCKEDOUTOFTRANSPORT HYDRAULICSSUSPENDED 0 0 37 SWINGENVELOPEENCROACHED HYDRAULICSSUSP...

Страница 544: ...TIONCHECKPRESSURESENSOR LOW 2 3 23131 MODELCHANGED HYDRAULICSSUSPENDED CYCLEEMS 2 5 259 GENERATORMOTIONCUTOUTACTIVE 2 5 2513 BOOMPREVENTED DRIVESELECTED 2 5 2514 DRIVEPREVENTED BOOMSELECTED 2 5 2515 D...

Страница 545: ...VEPUMP SHORTTOGROUND 3 3 3320 RIGHTREVERSEDRIVEPUMP OPENCIRCUIT 3 3 3321 RIGHTREVERSEDRIVEPUMP SHORTTOBATTERY 3 3 3322 LEFTFORWARDDRIVEPUMP SHORTTOGROUND 3 3 3324 LEFTFORWARDDRIVEPUMP OPENCIRCUIT 3 3...

Страница 546: ...3 3 3377 HEADTAILLIGHT SHORTTOBATTERY 3 3 3378 HOURMETER SHORTTOGROUND 3 3 3379 HOURMETER OPENCIRCUIT 3 3 3380 HOURMETER SHORTTOBATTERY 3 3 3381 PLATFORMLEVELUPOVERRIDEVALVE SHORTTOGROUND 3 3 3385 PL...

Страница 547: ...3134 PLATFORMCONTROLVALVE SHORTTOBATTERY 3 3 33135 MAINLIFTAPUVALVE SHORTTOGROUND 3 3 33136 MAINLIFTAPUVALVE OPENCIRCUIT 3 3 33137 MAINLIFTAPUVALVE SHORTTOBATTERY 3 3 33138 MAINLIFTPILOT PRESSUREFAILU...

Страница 548: ...TERY 3 3 33169 RESTRICTEDTOTRANSPORT AXLELOCKOUTVALVE SHORTTOBATTERY OROPENCIRCUIT 3 3 33173 RESTRICTEDTOTRANSPORT BRAKE SHORTTOBATTERYOROPENCIR CUIT 3 3 33174 JIBROTATELEFTVALVE OPENCIRCUIT 3 3 33175...

Страница 549: ...ACKREADINGTOOLOW 3 3 33414 SWING CURRENTFEEDBACKREADINGLOST 3 3 33418 JIBLIFTUPOVERRIDEVALVE SHORTTOGROUND 3 3 33429 JIBLIFTUPOVERRIDEVALVE OPENCIRCUIT 3 3 33430 JIBLIFTUPOVERRIDEVALVE SHORTTOBATTERY...

Страница 550: ...LEVELUPVALVE SHORTTOGROUND 3 4 343 PLATFORMLEVELUPVALVE SHORTTOBATTERYOROPENCIRCUIT 3 4 344 PLATFORMLEVELDOWNVALVE SHORTTOGROUND 3 4 347 PLATFORMLEVELDOWNVALVE SHORTTOBATTERYOROPENCIRCUIT 3 4 348 JIBL...

Страница 551: ...EADINGLOST 3 6 3612 REARAXLEEXTENDVALVE OPENCIRCUIT 3 6 3613 FRONTAXLEVALVE CURRENTFEEDBACKREADINGTOOLOW 3 6 3514 REARAXLERETRACTVALVE OPENCIRCUIT 3 6 3615 REARAXLEVALVE CURRENTFEEDBACKREADINGTOOLOW 3...

Страница 552: ...AGE 4 5 455 TOWERTELESCOPEPVGVALVE HIGHVOLTAGE 4 5 456 MAINLIFTPVGVALVE LOWVOLTAGE 4 5 457 TOWERLIFTPVGVALVE LOWVOLTAGE 4 5 458 TOWERTELESCOPEPVGVALVE LOWVOLTAGE 4 5 459 MAINLIFTPVGVALVE STUCKNEUTRAL...

Страница 553: ...TOWERTELESCOPEPVGVALVE PARAMETERSINCORRECT 4 5 4536 MAINLIFTPVGVALVE LOCATIONIMPROPER 4 5 4537 TOWERLIFTPVGVALVE LOCATIONIMPROPER 4 5 4538 TOWERTELESCOPEPVGVALVE LOCATIONIMPROPER 4 5 4539 MAINLIFTPVG...

Страница 554: ...SSISTILTSENSORDISAGREEMENT 8 1 815 CHASSISTILTREADINGDISAGREEMENT 8 1 8111 LSSCELL 1ERROR 8 2 821 LSSCELL 2ERROR 8 2 822 LSSCELL 3ERROR 8 2 823 LSSCELL 4ERROR 8 2 824 LSSHASNOTBEENCALIBRATED 8 2 825 R...

Страница 555: ...NOTCALIBRATED 8 3 8329 JIBSWINGSENSORS DISAGREEMENT 8 3 8330 JIBLOCKPINSENSOR DISAGREEMENT 8 3 8331 JIBTRANSPORTSENSOR 1 DISAGREEMENT 8 3 8332 JIBTRANSPORTSENSOR 2 DISAGREEMENT 8 3 8333 JIBLIFTANGLESE...

Страница 556: ...WERLENGTHSENSOR 2 OUTOFRANGEHIGH 8 4 8426 TOWERLENGTHSENSOR 2 OUTOFRANGELOW 8 4 8427 TOWERANGLESENSOR 1 INVALIDANGLE 8 4 8428 TOWERANGLESENSOR 2 INVALIDANGLE 8 4 8429 TOWERANGLESENSOR 1 INVALIDMODEL 8...

Страница 557: ...MULTIPLEFAILURESACTIVE 8 4 8487 MAINCYLINDERANGLESENSOR 2 OUTOFRANGELOW 8 4 8492 MAINCYLINDERANGLESENSOR 2 OUTOFRANGEHIGH 8 4 8493 MAINCYLINDERANGLESENSORS DISAGREEMENT 8 4 8494 TURNTABLESENSOR 1 FREQ...

Страница 558: ...864 AXLERETRACTVALVE SHORTTOGROUND 8 6 865 RIGHTFRONTSTEERRIGHTVALVE SHORTTOBATTERYOROPENCIRCUIT 8 6 866 RIGHTFRONTSTEERRIGHTVALVE SHORTTOGROUND 8 6 867 RIGHTFRONTSTEERLEFTVALVE SHORTTOBATTERYOROPENC...

Страница 559: ...ENGINESHUTDOWN AXLELOCKOUTVALVEFAULT 8 6 8651 RIGHTFRONTSTEERRIGHTVALVE OPENCIRCUIT 8 6 8670 RIGHTFRONTSTEERRIGHTVALVE SHORTTOBATTERY 8 6 8671 RIGHTFRONTSTEERLEFTVALVE OPENCIRCUIT 8 6 8672 RIGHTFRONT...

Страница 560: ...DSENSORREFVOLTAGEOUTOFRANGE 9 9 9919 PLATFORMSENSORREFVOLTAGEOUTOFRANGE 9 9 9920 GROUNDMODULEFAILURE HIGHSIDEDRIVERCUTOUTFAULTY 9 9 9921 PLATFORMMODULEFAILURE HWFSCODE1 9 9 9922 GROUNDMODULEFAILURE HW...

Страница 561: ...SUMINCORRECT 9 9 9945 LOADPINNOTCALIBRATED 9 9 9975 LSSCORRUPTEEPROM 9 9 9977 FUNCTIONSLOCKEDOUT GROUNDMODULESOFTWAREVERSION IMPROPER 9 9 9979 JIBCONTROLMODULE HIGHRESOLUTIONA2DFAILURE 9 9 99155 JIBCO...

Страница 562: ...treportedduringpower up 0015 0 15 LOADSENSORREADINGUNDERWEIGHT LSShasbeencalibratedandtheUGMhas determinedthattheloadsensingsystem readingislessthan 50lbsfor2seconds If theloadsensingsystemdeterminest...

Страница 563: ...lt ageis 8 1V Resistivejoysticks Ifthereferencevoltageis 7 7Vthenthereference voltageisoutoftoleranceofashorttobatteryhas occurred 2220 2 2 L SJOY CENTERTAPBAD TheL SJoystickcentertapvolt ageis 3 08Vo...

Страница 564: ...CTED Drivingisnotpossiblewhilethevehicle aboveelevationANDisconfiguredtopre ventdrivewhileaboveelevation 2516 2 5 DRIVEPREVENTED ABOVEELEVATION DrivingisnotpossiblewhileBoomfunc tionsareselectedANDisc...

Страница 565: ...theBrake Valve 332 3 3 BRAKE OPENCIRCUIT ThereisanOpenCircuittotheBrakeValve 3311 3 3 GROUNDALARM SHORTTOBATTERY ThereisaShorttoBatterytotheGround Alarm GroundAlarmequippedvehiclesonly 3316 3 3 RIGHTF...

Страница 566: ...LDSTARTADVANCESOLENOID OPEN CIRCUIT ThereisanOpenCircuittothe ColdStartAdvanceSolenoid CATenginesonly 3345 3 3 COLDSTARTADVANCESOLENOID SHORT TOBATTERY ThereisaShorttoBatterytothe ColdStartAdvanceSole...

Страница 567: ...3 3 PLATFORMLEVELUPOVERRIDEVALVE SHORTTOGROUND ThereisaShorttoGroundtothePlatform LevelUpOverrideValve Electroniclevelingsystemequippedvehiclesonly 3386 3 3 PLATFORMLEVELUPOVERRIDEVALVE OPENCIRCUIT Th...

Страница 568: ...ehiclesonly 33152 3 3 LIFTPILOTVALVE SHORTTOBATTERY ThereisaShorttoBatterytotheLiftPilot Valve GravityLiftDownequippedvehiclesonly 33153 3 3 LIFTDOWNAUXVALVE SHORTTOGROUND ThereisaShorttoGroundtotheLi...

Страница 569: ...heMainTele scopeFlowControlValve 33311 3 3 MAINLIFTFLOWCONTROLVALVE SHORT TOGROUND ThereisaShorttoGroundtothe MainLiftFlowControlValve 33312 3 3 MAINLIFTFLOWCONTROLVALVE OPEN CIRCUIT ThereisanOpenCirc...

Страница 570: ...BATTERY ShorttoBatterydetected Checkwiring 33563 3 3 LIFTENABLEVALVE STUCKOPEN Liftpilotvalveisenergized duringauxil iaryorgravitysequence and1degof motionisdetectedpriortotheenablevalve beingenergiz...

Страница 571: ...5 JIBLIFTUPVALVE SHORTTOBATTERYOR OPENCIRCUIT 357 3 5 JIBLIFTDOWNVALVE SHORTTOGROUND 358 3 5 JIBLIFTDOWNVALVE SHORTTOBATTERY OROPENCIRCUIT 359 3 5 JIBROTATELEFTVALVE SHORTTOGROUND 3510 3 5 JIBROTATELE...

Страница 572: ...XLEVALVE CURRENTFEEDBACK READINGTOOLOW Currentfeedbackintocontrollerisbelow thresholdvalue Checkwiringandcoil 3615 3 6 REARAXLERETRACTVALVE OPENCIRCUIT OpenCircuitdetected Checkwiring 3616 3 6 REARAXL...

Страница 573: ...TED SCRCleaningwasrequestedbunotiniti ated 4365 4 3 RUNNINGATCREEP ENGINEPOWER REDUCTION Triggeredby524190 14 enginecon trolled 4366 4 3 SCRCLEANINGREQUIRED SOOTDETECTED SCRCrystallizationhasbeendetec...

Страница 574: ...TAGE NOTCALIBRATED TheshearbeamisreportingaSensorSup plyVoltagecalibrationerror Themachinewillassumetheplatformis overloaded Thisfault onceannunciatedislatched withinagivenkeycycle Possiblesensorhardw...

Страница 575: ...dwareandwiring 815 8 1 CHASSISTILTSENSORDISAGREEMENT X 8111 8 1 CHASSISTILTREADINGDISAGREEMENT Disagreementbetweeninternal UGM and externalchassistiltsensors Checkexternal internalsensorhardwareandins...

Страница 576: ...mhasdeterminedthatthe straingauge1readingintheloadsensoris stagnant notchanging Iftheplatformisnotconsideredtobeover loadedboomfunctionswillberestrictedto creep IfDTC8223isactiveincombinationwith DTC8...

Страница 577: ...nunciatedislatched withinagivenkeycycle Possiblesensorhardwareissue 8226 8 2 LSSSTRAINGAUGE1 OUTOFRANGEHIGH Theshearbeamisreportinganoutofrange highissuewiththestraingauge1reading Iftheplatformisnotov...

Страница 578: ...unciatedislatched withinagivenkeycycle Possiblesensorhardwareissue 8230 8 2 LSSSTRAINGAUGE1 NOTCALIBRATED Theshearbeamisreportingacalibration issuewiththestraingauge1sensor Iftheplatformisnotoverloade...

Страница 579: ...anotinstalled issuewiththestraingauge1sensor Iftheplatformisnotoverloadedthe machinewillbeplacedintocreep IfDTC8235isalsoactivethemachinewill assumetheplatformisoverloaded Thisfault onceannunciatedisl...

Страница 580: ...8 2 RUNNINGATCREEP PLATFORMOVER LOADED Allfunctionsatcreep theLoadSensingSys temindicatesthePlatformisoverloaded ANDisconfiguredtowarnonlywhilethe Platformisoverloaded 827 8 2 DRIVE BOOMPREVENTED PLAT...

Страница 581: ...5 1 volts Electroniclevelingsystemequippedvehiclesonly 8315 8 3 PLATFORMLEVELINGSENSOR DISAGREE MENT TheControlSystemreadsthesensorvalues atpower up Thefaultistriggeredwhen thereisa 5degreedifferencef...

Страница 582: ...ENSOR VALUEOUTOF RANGEHIGH BoomLengthoutofrangehigh EnvelopeControlequippedvehiclesonly 848 8 4 BOOMLENGTHSENSOR VALUEOUTOF RANGELOW BoomLengthoutofrangelow EnvelopeControlequippedvehiclesonly 849 8 4...

Страница 583: ...ANDDRIVE ORIENTATIONSWITCH DIS AGREEMENT 84101 8 4 CHASSISTURNTABLESENSORS NOTCALI BRATED 84102 8 4 MAINCYLINDERANGLESENSOR NOT DETECTINGCHANGE 84103 8 4 JIBLEVELANGLESENSOR NOTDETECTING CHANGE 84104...

Страница 584: ...heditsthreshold Thisvalueis storedinEEPROMinordertotrackthehis toryoftheissue AsuccessfulBoomSensor Calibrationwillresetthiscounter thisis reflectedintheboomsensorcalibration document TwrLenSnsr 1 2 F...

Страница 585: ...heditsthreshold Thisvalueis storedinEEPROMinordertotrackthehis toryoftheissue AsuccessfulBoomSensor Calibrationwillresetthiscounter thisis reflectedintheboomsensorcalibration document TwrLenSnsr 1 2 F...

Страница 586: ...ditsthreshold Thisvalueis storedinEEPROMinordertotrackthehis toryoftheissue AsuccessfulBoomSensor Calibrationwillresetthiscounter thisis reflectedintheboomsensorcalibration document BmLenSnsr 1 2 Faul...

Страница 587: ...sensorcalibration document BmLenSnsr 1 2 FaultCounter_EEPROM 3 c Thefaultcounterbelowshallbeincre mentedeverytimethetriggercondition describedinsection a isobservedduring certainstepsduringBoomSensorC...

Страница 588: ...penCircuit totheLeftFrontSteerRightValve 8611 8 6 LEFTFRONTSTEERRIGHTVALVE SHORTTO GROUND ThereisaShorttoGroundtothe LeftFrontSteerRightValve 8612 8 6 LEFTFRONTSTEERLEFTVALVE SHORTTO BATTERYOROPENCIRC...

Страница 589: ...ghtSteerSensor 8631 8 6 FRONTRIGHTSTEERSENSOR SHORTTO BATTERY ThereisaShorttoBatterytothe FrontRightSteerSensor 8632 8 6 FRONTLEFTSTEERSENSOR SHORTTO GROUNDOROPENCIRCUIT ThereisaShorttoGroundoranOpenC...

Страница 590: ...IT OpenCircuitdetected 8681 8 6 RIGHTREARSTEERLEFTVALVE SHORTTO BATTERY ShorttoBatterydetected 8682 8 6 LEFTREARSTEERRIGHTVALVE OPENCIR CUIT OpenCircuitdetected 8683 8 6 LEFTREARSTEERRIGHTVALVE SHORTT...

Страница 591: ...ringpower up 9920 9 9 PLATFORMSENSORREFVOLTAGEOUTOF RANGE ThePlatformModulehasreportedthatits sensorreferencevoltageisoutsideaccept ablerange Notreportedduringpower up 9921 9 9 GROUNDMODULEFAILURE HIG...

Страница 592: ...SUPPLYOUTOFRANGELOW TheBoomAngleSensorssupplyvoltageis low BLAMequippedvehiclesonly 9937 9 9 LENGTHSENSORREFVOLTAGEHIGH TheBoomLengthSensorssupplyvoltageis high 9938 9 9 LENGTHSENSORREFVOLTAGELOW TheB...

Страница 593: ...amaging the seal around the wire It is best to use probes or probe tips specifically designed for this technique especially on sealed connectors Whenever possible insert probes into the side of the co...

Страница 594: ...uto ranging set it to the correct range See multimeter s operation manual Use firm contact with meter leads Continuity Measurement Some meters require a separate button press to enable audible continu...

Страница 595: ...e and female pins To prevent electrical malfunction caused by low level con ductivity between pins when wet Use the following procedure to apply Silicone Dielectric Com pound to the electrical connect...

Страница 596: ...yringe for small connectors 2 Apply dielectric grease to the female contact fill it approximately full see example below 3 Leave a thin layer of dielectric grease on the face of the connector 4 Assemb...

Страница 597: ...IN Connectors This connector is typically used on hydraulic valves Follow the installation instructions Exclusions A limited number of connectors do not benefit from dielectric grease or may be perman...

Страница 598: ...ractical way to remove the dielectric grease replacement of female contacts required The JLG Load Sensing System and 1250AJP Rotary Angle Sensors are examples of components with the M12 con nector sys...

Страница 599: ...ipped position See Figure 7 7 Proceed as follows 1 To insert a contact push it straight into the appropriate circuit cavity as far as it will go See Figure 7 9 2 Pull back on the contact wire with a f...

Страница 600: ...edge lock must be closed to its locked position Release the locking latches by squeezing them inward See Figure 7 10 4 Slide the wedge lock into the housing until it is flush with the housing See Figu...

Страница 601: ...e forward or mating end These slots accommodate circuit testing in the field by using a flat probe such as a pocket knife DO NOT use a sharp point such as an ice pick Service Voltage Reading DO NOT PI...

Страница 602: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 10 3121619 Figure 7 13 Connector Installation...

Страница 603: ...ward exterior locking mechanism The wedgelock will snap into place Rectangular wedges are not oriented Thy may go in either way NOTE The receptacle is shown use the same procedure for plug DT DTP Seri...

Страница 604: ...wire cavities insert sealing plugs for full envi ronmental sealing HD30 HDP20 Series Disassembly 1 With rear insert toward you snap appropriate size extractor tool over the wire of contact to be remo...

Страница 605: ...eFuelUsed Totalamountoffuelusedduringvehicleoperationduringidleconditions Liters TotalIdleHours Totaltimeofengineoperationduringidleconditions Seconds TotalEngineHours Totaltimeofengineoperation Secon...

Страница 606: ...RICAL INFORMATION ELECTRICAL SCHEMATICS 7 14 3121619 MS1619 3 MS1619 1 MS1619 2 X1609 MS1620 1 S1614 S1615 MS1618 2 MS1620 3 MS1620 2 MS1618 3 CO1613 J2 CO1613 J1 X1606 Figure 7 20 Telematics Gateway...

Страница 607: ...RN CANL2 18 AWG GXL MS1619 2 B 10 YEL CANH2 18 AWG GXL MS1619 2 A MS1619 3 CAN T 2 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO A YEL CANH2 18 AWG GXL MS1620 2 A B GRN CANL2 18 AWG GXL MS1620 2 B MS...

Страница 608: ...18 AWG 155 GXL X1609 10 MS1619 2 A CAN H2 YEL 18 AWG 233 GXL MS1620 3 A CO1613 J2 10 CAN H1 YEL 18 AWG 157 GXL MS1618 2 A CO1613 J1 10 CAN H2 YEL 18 AWG 1150 GXL MS1619 3 A MS1620 2 A CAN H1 YEL 18 A...

Страница 609: ...o the table below followed by a unique sequential number An optional suffix letters numbers may be added when multiple terminations occur at one device Terminals that are not loaded into connectors ar...

Страница 610: ...tch SW Sensor Angle SN Fuel Length Limit Load Pressure Proximity Speed Temperature Terminals Pins T Sockets MaleBlades FemaleBlades Rings Forks ToggleSwitch DPDT SW DPST SPDT SPST Special Valves Simpl...

Страница 611: ...SW 22 2 SW2 3 M AIN BO OM T ELE SW 21 JIB L IF T SW 19 JIB SWI NG SW1 4 J IB T EL E SW 13 PLT FM R OTAT E X38 8 X38 5 X39 0 X3 8A X38 7 X39 9 X39 1 X3 84 X3 98 AH 30 AH 30 X32 CO 01 J2 CO0 1 J1 X3 3A...

Страница 612: ...GD04 J4 4 13 WHT 54 2 1000LBMODE 18 AWG GXL GD04 J3 4 14 WHT 39 1 AXL SET 18 AWG GXL GD04 J3 2 15 WHT 52 1 GEN 18 AWG GXL GD04 J4 2 16 WHT 49 21 SFTCH LT 18 AWG GXL LB12 1 17 WHT 48 1 ENG PREHEAT 18...

Страница 613: ...J7 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 YEL 2 5 18 AWG GXL X33A 11 2 RED 1 4 3 PLTF MODE 18 AWG GXL SW35 1A 1A 3 YEL 2 4 18 AWG GXL X33A 4 4 BRN 49 11 X43 PWR 20 AWG CABLE X43A 1 5 WHT 23...

Страница 614: ...ELECTRICAL SCHEMATICS 7 22 3121619 SN273 MS437 X36B HV281 PLTFM ENABLE HV275 P LVL UP HV278 P ROT RHT HV277 P ROT LFT HV276 P LVL DN HV342 JLOCK IN HV343 JLOCK OUT X365B Figure 7 26 Platform Valve Wi...

Страница 615: ...E COLOR WIRE LABEL GAUGE JACKET TO 1 ORG CABLE 18 AWG CABLE X36B 15 2 YEL CABLE 18 AWG CABLE X36B 16 3 BLK CABLE 18 AWG CABLE X36B 17 HV281 PLTFM ENABLE CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO...

Страница 616: ...2 JIB DN 18 AWG GXL HV253 1 S383 CONN P OS WIRE COLOR WIRE LABEL GAUGE J ACK ET TO 1 BLK 0 27 18 AWG GX L MS380 12 2 BLK 0 27 1 18 AWG GX L SN259 3 2 BLK 0 47 16 AWG GX L HV248 2 X230A X228B SN260 CO...

Страница 617: ...245 J2 6 HV256 JIB LVL UP CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 WHT 55 20 JLVL UP 18 AWG GXL CO245 J2 11 2 BLK 0 25 1 18 AWG GXL MS347 8 HV250 JIB SWG RHT CONN POS WIRE COLOR WIRE LABEL GAU...

Страница 618: ...26 18 AWG GXL MS347 12 CO245 J2 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 WHT 27 3 1 JIB DN O R 18 AWG GXL S265 1 2 WHT 27 6 1 J UP O R 18 AWG GXL S264 1 3 BLK 0 25 18 AWG GXL MS347 11 4 WHT 4...

Страница 619: ...SIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 27 C O1 28 J5 CO128 J3 X411 SN13 0 CO12 8 J1 CO1 28 J2 X4 06A MS1 48 1 X421 X4 13 X2 22B Figure 7 31 BLAM Module Wiring Harness Sheet 1 of 2...

Страница 620: ...1 18 AWG GXL X406A 2 9 WHT 49 61 GRVTY SEN2 18 AWG GXL X406A 6 10 11 WHT 7 1 RDRV PFWD 18 AWG GXL X222B 1 12 WHT 7 2 RDRV PREV 18 AWG GXL X222B 2 X406A CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1...

Страница 621: ...JACKET A RED B PWR SUP 22 PVC B BLK B GND SUP 22 PVC C D GRN CAN HI 22 PVC E WHT CAN LO 22 PVC F CO128 J4 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET 1 RED B PWR SUP 22 PVC 2 BLK B GND SUP 22 PVC 3 G...

Страница 622: ...UE 1 ANGLE SIG 18 AWG CABLE C BLACK 1 ANGLE GND 18 AWG CABLE X406B CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET 1 RED 1 ANGLE PWR 18 AWG CABLE 2 BLUE 1 ANGLE SIG 18 AWG CABLE 3 BLACK 1 ANGLE GND 18 AWG...

Страница 623: ...G CABLE 6 ORANGE BRKN CBL SIG 18 AWG CABLE 7 BROWN BRKN CBL GND 18 AWG CABLE 8 SHIELD CABLESHIELD 18 AWG CABLE X404A CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET 1 RED BLNTH PWR 18 AWG CABLE 2 BLUE BLN...

Страница 624: ...G CABLE SN131 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET A RED BLNTHPWR 18 AWG CABLE C BLUE BLNTHSIG 18 AWG CABLE B BLACK BLNTHGND 18 AWG CABLE SN401 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET 1 BRO...

Страница 625: ...EMATICS 3121619 7 33 X407B A C B 1 4 3 2 1 4 3 2 SN221 SN401 SN131 S40 9 S4 10 BRKN CBL PWR BRKN CBL SIG BRKN CBL GND BRKN CBL GND 1 BRKN CBL GND 2 BRKN CBL PWR 1 BRKN CBL SIG 1 B LNTH PWR B LNTH SIG...

Страница 626: ...HT BECON PWR 16 AWG CABLE BEACON SIDE CONNECTION 2 BLK BECON GND 16 AWG CABLE BEACON SIDE CONNECTION BEACON SIDE CONNECTION CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 WHT BEACON PWR 16 AWG CABLE...

Страница 627: ...2 BL K 14 8 5 7 WT R F UL RTN 1 6 AW G GXL X9 4 2 2 X94 2 CONN POS WIRE COLOR WI R E L ABEL G AUGE JACKET TO 1 BLK 1 4 8 6 4 WTR FUL SW 1 6 AWG GXL SN95 9 1 2 BLK 1 4 8 5 7 WT R F UL RTN 1 6 AWG GXL S...

Страница 628: ...DIODE DETAILS RL360 85 RL360 86 R L127 86 RL234 85 RL234 86 IP91 IP90 X378 X373 X376 X362 X418 X377 X375 X237 RL235 Y X353 RL235 R RL236 Y RL236 R X147A X149A X217A X218A S372 S239 S371 X159B RL127 85...

Страница 629: ...18 AWG GXL IP90 1 IP91 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 RED 1 4 2 1 18 AWG GXL RL234 86 1 2 RED 1 4 2 18 AWG GXL X327B 4 IP90 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 YEL 2 4 2...

Страница 630: ...AWG GXL X81 12 X353 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 YEL 2 12 18 AWG GXL X327B 5 1 YEL 2 17 18 AWG GXL LB417 1 RL235 R CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 YEL 2 1 99 IGNIT...

Страница 631: ...1 YEL 2 1 99 IGNITION 18 AWG GXL S372 2 2 BLK 0 17 16 AWG GXL CO02 J1 8 3 WHT 52 9 GEN 18 AWG GXL CO02 J1 22 4 WHT 48 7 GLOW 18 AWG GXL CO02 J1 12 5 YEL 2 13 16 AWG GXL RL235 R 1 6 BLK 0 18 18 AWG GX...

Страница 632: ...RMATION ELECTRICAL SCHEMATICS 7 40 3121619 X81 SN123 LB417 X84 X327B X412 CO02 J7 X88 CO02 J1 IP85 S89 X440B X420 S456 CO02 J12 CO02 J8 MS83 MS148 2 MS148 3 X468 S469 X395 X467 MS82 Figure 7 44 Turnta...

Страница 633: ...18 AWG GXL CO02 J7 1 LB417 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 YEL 2 17 18 AWG GXL X353 1 2 BLK 0 16 18 AWG GXL X237 1 X420 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 BLK 0 50 1 16...

Страница 634: ...20 AWG J1939 CABLE S469 2 7 SHLD CANSHLD 20 AWG J1939 CABLE MS148 3 C 8 9 GRN CANLO 20 AWG J1939 CABLE X81 2 10 GRN CANLO 20 AWG J1939 CABLE MS148 3 B 11 YEL CANHI 20 AWG J1939 CABLE X81 3 12 YEL CAN...

Страница 635: ...WHT 49 77 PC PWR 20 AWG GXL X440B 2 27 WHT 49 64 TILT PWR 18 AWG GXL X395 1 28 29 WHT BLNTH CBL 18 AWG CABLE SN123 4 30 WHT JUMPER3 18 AWG GXL CO02 J7 23 31 32 RED CABLE 18 AWG CABLE X412 5 33 34 YEL...

Страница 636: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 44 3121619 MS148 2 MS83 MS82 X395 Figure 7 48 Turntable Wiring Harness Sheet 9 of 9...

Страница 637: ...T AUX SW 64 PLATF LVL LB 76 1000 CAP LB 6 8 AXLE SET LB 75 PLATF OVRLD LB 73 MOMNT CNTRL LB 71 LO OIL LB 72 NO ALT SW66 1 SW66 2 LB 70 HI TEMP LB 74 BOOM CNTRL LB 69 GL OW PLUG L B 67 5 00 CAP SW 63 P...

Страница 638: ...N POS WIRE COLOR W IRE LABEL GAUGE JACKET TO 1 WHT 23 5 P ROTRHT 18 AWG GXL CO02 J4 18 2 YEL 2 9 6 18 AWG GXL SW62 2 2 YEL 2 9 8 18 AWG GXL SW64 2 3 WHT 23 6 P ROTLFT 18 AWG GXL CO02 J4 6 LB67 CONN PO...

Страница 639: ...9 3 JIB IN 18 AWG GXL CO02 J4 11 2 YEL 2 9 4 18 AWG GXL SW66 1 1 2 YEL 2 9 5 18 AWG GXL SW62 2 3 WHT 29 4 JIB OUT 18 AWG GXL CO02 J4 22 SW60 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 WHT 13 5 T...

Страница 640: ...S 244 HV 176 LE FT RE AR ST R RHT HV 172 LEF T FRONT S TR RHT HV 163 RE AR AX LE S WG EX T HV 164 RE AR AX LE S WG RET HV 173 LE FT FRONT S TR LFT HV 177 LE FT REA R ST R LFT S 204 S 202 S168 HV 175 R...

Страница 641: ...L GAUGE JACKET T O 1 WHT 38 6 RAXS RET 18 AWG GXL CO03 J2 7 2 WHT 60 5 2 RAXS RTN 18 AWG GXL S168 2 HV173 LEFT FRONT STR LFT CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 WHT 9 3 LF RNT STRL 18 AWG...

Страница 642: ...RHT FRNT STR 18 AWG CABLE CO03 J7 4 4 SHIELD SHLD 18 AWG SHLD S424 2 5 6 S167 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 WHT 60 4 FAXS RTN 18 AWG GXL CO03 J3 1 2 WHT 60 4 1 FAXS RTN 18 AWG GXL H...

Страница 643: ...R STRR 18 AWG GXL HV176 1 10 11 WHT 9 4 RFRNT STRR 18 AWG GXL HV170 1 12 13 WHT 55 14 BRAKE 18 AWG GXL HV179 1 14 BLK 00 1 18 AWG GXL S181 1 15 16 WHT 38 3 FAXS RET 18 AWG GXL HV162 1 17 BLK 00 3 18 A...

Страница 644: ...L S195 1 10 11 12 13 14 WHT 38 10 FAXS LFT 18 AWG GXL X449B 2 15 WHT 38 9 RAXS RHT 18 AWG GXL X448B 2 16 WHT 55 15 TTABLE ANG 18 AWG GXL SN243 C 17 18 BLK 00 14 18 AWG GXL SN243 A 19 20 21 22 23 24 25...

Страница 645: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 53 Figure 7 57 Chassis Harness Sheet 6 of 6...

Страница 646: ...FL OW CNTRL H V316 WARM UP VLV X158 AH 318 SN11 4 FUEL LEVEL C O0 2 J3 CO02 J2 S15 7 S1 56 S1 55 S154 S1 53 HV10 8 TEL E FLOW CN TR L SN 438 SN43 9 H V315 LIFT EN ABLE X440 A S45 5 H V103 MAIN TELE OU...

Страница 647: ...2 19 2 WHT 60 1 LFCNTRL RTN 18 AWG GXL CO02 J3 1 HV348 SWG FLOW CNTRL CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 WHT 55 32 SWG F C 18 AWG GXL CO02 J2 35 2 WHT 60 3 SWG RTN 18 AWG GXL CO02 J3 4 X...

Страница 648: ...10 FUL SEN 18 AWG GXL CO02 J2 25 2 BLK 0 14 3 18 AWG GXL S157 2 S153 CONNECTOR PART NUM BER SPLICE CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TERM INAL P N TO 1 BLK 0 30 18 AWG GXL N A CO02 J2 18 2...

Страница 649: ...8 AWG GXL X222A 3 1 BLK 0 15 3 18 AWG GXL HV144 2 1 BLK 0 15 4 18 AWG GXL HV145 2 2 BLK 0 15 1 18 AWG GXL HV142 2 2 BLK 0 15 2 18 AWG GXL HV143 2 HV142 RHT DRV PUMP FWD CONN POS WIRE COLOR WIRE LABEL...

Страница 650: ...58 3121619 SN939 RL930 T920 RL931 85 RL931 86 RL931 87 RL930 1 RL930 2 FC1003 FC1004 X 1006 X950 MS1002 2 S 1008 X1009 MS999 1 EC241 L X217B X941 X218B S1011 S945 S944 ECM J2 MS1001 1 E CM J1 MS 1000...

Страница 651: ...75 mm FLRYW EIC 52 39 40 41 42 43 44 BLK 148 44EHXAUST GAS RECIRCULATION 0 75 mm FLRYW EIC 50 45 46 47 48 49 50 51 52 53 GRN CAN LOW 0 75 mm FLRYW MS1000 1 B 54 YEL CAN HIGH 0 75 mm FLRYW MS1001 1 A 5...

Страница 652: ...4 27 BLK 248 29 OIL PRESSURE 0 75 mm FLRYW ECM J2 29 28 BLK 248 40 AIR INLET TEMP 0 75 mm FLRYW ECM J2 40 29 BLK 248 27 BOOST PRESSURE TEMP 0 75 mm FLRYW ECM J2 27 30 31 BLK 248 25 RAIL PRESSURE FUEL...

Страница 653: ...LRYW EIC 25 27 BLK 248 27 BOOST PRESSURE TEMP 0 75 mm FLRYW EIC 29 28 BLK 248 28COOLING TEMPERATURE 0 75 mm FLRYW EIC 24 29 BLK 248 29 OIL PRESSURE 0 75 mm FLRYW EIC 27 30 31 32 BLK 248 32 INJECTOR 3...

Страница 654: ...CAN LOW 20 AWG J1939 CABLE MS1001 2 B C SHLD SHIELD 20 AWG J1939 CABLE MS1001 2 C MS999 3 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO A YEL CAN HI 20 AWG J1939 CABLE X1005 1 B GRN CAN LOW 20 AWG J...

Страница 655: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 63 MS1000 2 X1005 MS1002 1 MS999 3 MS999 2 Figure 7 67 CAN Engine Harness Sheet 2 of 2...

Страница 656: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 64 3121619 Figure 7 68 Generator Enable Harness Sheet 1 of 2...

Страница 657: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 65 Figure 7 69 Generator Enable Harness Sheet 1 of 2...

Страница 658: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 66 3121619 Figure 7 70 T4F Engine Harness Sheet 1 of 14...

Страница 659: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 67 Figure 7 71 T4F Engine Harness Sheet 2 of 14...

Страница 660: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 68 3121619 Figure 7 72 T4F Engine Harness Sheet 3 of 14...

Страница 661: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 69 Figure 7 73 T4F Engine Harness Sheet 4 of 14...

Страница 662: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 70 3121619 Figure 7 74 T4F Engine Harness Sheet 5 of 14...

Страница 663: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 71 Figure 7 75 T4F Engine Harness Sheet 6 of 14...

Страница 664: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 72 3121619 Figure 7 76 T4F Engine Harness Sheet 7 of 14...

Страница 665: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 73 Figure 7 77 T4F Engine Harness Sheet 8 of 14...

Страница 666: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 74 3121619 Figure 7 78 T4F Engine Harness Sheet 9 of 14...

Страница 667: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 75 Figure 7 79 T4F Engine Harness Sheet 10 of 14...

Страница 668: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 76 3121619 Figure 7 80 T4F Engine Harness Sheet 11 of 14...

Страница 669: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 77 Figure 7 81 T4F Engine Harness Sheet 12 of 14...

Страница 670: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 78 3121619 Figure 7 82 T4F Engine Harness Sheet 13 of 14...

Страница 671: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 79 Figure 7 83 T4F Engine Harness Sheet 14 of 14...

Страница 672: ...NFORMATION ELECTRICAL SCHEMATICS 7 80 3121619 X436B TO ENG HARN X734B TO ENG HARN SN238 UREA QUTY LVL TEMP X253 UREA SUP MOD X251 THRTLE HTR X250 SUCTION HTR X252 PRS HTR Figure 7 84 Urea Tank Supply...

Страница 673: ...238 1 X250 SUCTION HTR CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 YEL 2 60 3 2 5 mm FLRYW X436B 8 2 WHT 102 2 STION HTR 2 5 mm FLRYW X436B 7 X252 PRS HTR CONN POS WIRE COLOR WIRE LABEL GAUGE JAC...

Страница 674: ...AWG TFFN J7_24 1 2 YEL CANH_6 18 AWG TFFN J7_13 1 J7_13 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 YEL CANH_6 18 AWG TFFN MS377 1 2 J7_24 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 GRN CA...

Страница 675: ...CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 RED 103 18 AWG TFFN X383 1 1 BLK 119_1 14 AWG TFFN IP914 1 2 RED 115 18 AWG TFFN SW374 1 SW374 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 RED 11...

Страница 676: ...MS148 3 MS148 2 MS148 1 CO128 J5 CO128 J3 CO128 J1 X81 CONNECTS TO MAIN BOOM CABLE X341A CONNECTS TO 16 4 MAIN BOOM CABLE SN123 CONNECTS TO TRANSPORT SWITCH CABLE X406A CONNECTS TO BASE BOOM ANGLE SEN...

Страница 677: ...LV HV108 TELE FLOW CNTRL HV102 LIFT FLOW CNTRL HV348 SWG FLOW CNTRL HV104 MAIN DUMP HV109 MAIN TELE IN HV101 MAIN LIFT DN HV100 SWG LFT HV107 LIFT PILOT HV103 MAIN TELE OUT X159A HV105 LIFT DN AUX HV9...

Страница 678: ...406A X395 CONNECTS TO TILT SENSOR X412 X411 X84 LB417 SN959 SN123 X341A MS82 MS83 RL234 86 RL127 85 RL234 85 RL236 R RL235 Y RL236 Y X353 RL235 R RL127 86 RL360 85 RL360 86 X237 X362 X373 X375 X376 X3...

Страница 679: ...EMP LB69 GLOW PLUG LB68 AXLE SET LB67 500 CAP LB76 1000 CAP LB73 MOMNT CNTRL LB75 PLATF OVRLD LB74 BOOM CNTRL SW66 2 SW63 PLATF ROT SW64 PLATF LVL SW65 STRT AUX X77 M D I SW60 MAIN TELE SW61 JIB TELE...

Страница 680: ...TRICAL SCHEMATICS 7 88 3121619 IP415 IP379 BATTERY AND RELAYS IP414 EMERGENCY STOP AND KEY SWITCH SW56 1 GND MODE SW56 B E STOP B SW56 3 PLATF MODE SW55 2B E STOP B t SW55 1B BAT B Figure 7 92 Electri...

Страница 681: ...Y X338A CONNECTS TO STEER CABLE 2 OF 4 X340A CONNECTS TO STEER CABLE 1 OF 4 442A 448B 449B 445A X339A CONNECTS TO STEER CABLE 3 OF 4 X337A CONNECTS TO STEER CABLE 4 OF 4 X160 SN243 X147B HV179 HV178 S...

Страница 682: ...HT FRONT STR RHT HV174 RIGHT REAR STR RHT SECTION D D HV164 REAR AXLE SWG RET HV173 LEFT FRONT STR LFT HV177 LEFT REAR STR LFT HV163 REAR AXLE SWG EXT HV172 LEFT FRONT STR RHT HV176 LEFT REAR STR RHT...

Страница 683: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 91 Figure 7 95 Electrical Installation Sheet 8 of 10 1001156522 H...

Страница 684: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 92 3121619 Figure 7 96 Electrical Installation Sheet 9 of 10 1001156216 H...

Страница 685: ...SCHEMATICS 3121619 7 93 HV256 JIB LVL UP HV250 JIB SWG RHT HV248 JIB ENABLE HV254 JIB LIFT UP HV251 JIB TELE OUT HV255 JIB LVL DN HV253 JIB LIFT DN HV249 JIB SWG LFT HV252 JIB TELE IN Figure 7 97 Ele...

Страница 686: ...94 3121619 Figure 7 98 Battery Jump Start Hookup THIS MACHINE UTILIZES A 12 VOLT ELECTRICAL SYSTEM TO PREVENT DAMAGE WHEN JUMP STARTING THE MACHINE CONNECT THE JUMP START EQUIPMENT ONLY TO THE BATTER...

Страница 687: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 95 Figure 7 99 Battery Installation Sheet 1 of 2...

Страница 688: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 96 3121619 Figure 7 100 Battery Installation Sheet 2 of 2...

Страница 689: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 97 Figure 7 101 Electrical Schematic Sheet 1 of 21...

Страница 690: ...NT WHT 39 1 AXL SET WHT 39 1 AXL SET WHT 49 4 BCS WHT 49 4 BCS BLK 0 2 BLK 0 2 WHT 47 5 LOW FUL WHT 47 5 LOW FUL YEL 2 2 ENABLE YEL 2 2 ENABLE WHT 49 5 CREEP WHT 49 5 CREEP WHT 47 4 FUL FULL WHT 47 4...

Страница 691: ...OT BLK 0 3 BLK 0 3 WHT 49 15 SFT TOUCH WHT 49 15 SFT TOUCH WHT 27 1 JIB UP WHT 27 1 JIB UP WHT 27 2 JIB DN WHT 27 2 JIB DN WHT 52 3 HEAD TAIL LT WHT 52 3 HEAD TAIL LT WHT 13 1 MTELE IN WHT 13 1 MTELE...

Страница 692: ...7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 X36B 1 15 14 13 12 11 10 9 8 7 6 5 4 3 2 21 20 19 18 17 16 GRN GRN 1001145974_2 7 D WHT 25 3 2 PLVL UP WHT 25 3 2 PLVL UP WHT 25 4 2 PLVL DN WHT 25 4 2 PLVL D...

Страница 693: ...LK 0 26 5 BLK 0 26 4 BLK 0 26 3 BLK 0 26 2 BLK 0 26 1 WHT 55 19 JLVL DN WHT 55 19 JLVL DN WHT 55 20 JLVL UP WHT 55 20 JLVL UP BLK 0 25 S264 S265 BLK 0 25 2 BLK 0 25 1 WHT 27 3 1 JIB DN O R WHT 27 6 1...

Страница 694: ...5 7 D BLK 0 45 BLK 1 0 RED 1 0 RED 1 0 RED 1 7 WK LT PWR 12 IP379 RED 1 7 1 WK LT PWR 16 1001145974_5 8 E RED 1 7 2 WK LT PWR 16 RED 1 7 2 WK LT PWR 16 1001145974_5 8 E PROXIMITY SENSOR 2 BROKEN CABLE...

Страница 695: ...K 0 20 12 1001145974_5 5 B RED 1 15 1001145974_5 2 C RED 1 5 16 1001145974_5 1 E BLK 0 22 14 BLK 0 22 14 X353 1 YEL 2 17 YEL 2 17 BATTERY DISCONNECT SOLENOID RL360 87 1 RL360 30 1 RL360 86 1 RL360 85...

Страница 696: ...LO RED 1 4 3 RED 1 4 3 2 E 4 A RED 1 4 3 YEL CAN HI YEL CAN HI 1001145974_4 4 E GRN CAN LO GRN CAN LO 1001145974_4 4 E SHLD CAN SHLD SHLD CAN SHLD 1001145974_4 4 E WHT B LNTH CBL WHT B LNTH CBL 100114...

Страница 697: ...T 49 30 OVERLOAD WHT 49 30 OVERLOAD WHT 54 5 1000 WHT 54 5 1000 BLK 0 12 9 BLK 0 12 9 BLK 0 12 8 BLK 0 12 8 BLK 0 12 7 BLK 0 12 7 BLK 0 12 6 BLK 0 12 6 BLK 0 12 5 BLK 0 12 5 BLK 0 12 4 BLK 0 12 4 BLK...

Страница 698: ...1 2 5 6 7 8 3 4 WHT 61 1 5 5V 6 C WHT 61 1 6 5V 6 C WHT 55 18 TTABLE ANG2 X309 1 2 3 4 5 6 7 8 9 10 11 12 X147A 1 2 3 4 5 6 7 8 9 10 11 12 X311 1 2 3 4 5 6 7 8 9 10 11 12 YEL GRN BLK ORG DRIVE ORIENTA...

Страница 699: ...T 61 1 3 5V 5 H WHT 61 1 4 5V 6 C WHT 61 1 3 5V 7 C BLK 00 9 BLK 00 9 WHT 55 15 TTABLE ANG WHT 55 15 TTABLE ANG BLK 00 6 BLK 00 6 BLK 00 5 BLK 00 5 BLK 00 4 1 BLK 00 3 1 S202 BLK 00 4 BLK 00 4 S203 BL...

Страница 700: ...7 1 LDRV PFWD WHT 7 1 LDRV PFWD WHT 7 2 LDRV PREV WHT 7 2 LDRV PREV BLK 0 15 BLK 0 15 ENABLE CHASSIS HV314 1 2 ENABLE LIFT HV315 1 2 VALVE WARM UP HV316 1 2 WHT 55 33 WARM UP WHT 60 6 WARM UP RTN WHT...

Страница 701: ...55 31 CHS ENABLE WHT 55 30 LFT ENABLE BLK 0 36 BLK 0 36 MOTION ALARM HORN AH318 A B C WHT 52 8 ALRM PWR WHT 52 8 ALRM PWR BLK 0 30 BLK 0 30 WHT 60 7 LENABLE RTN WHT 60 7 LENABLE RTN FLOW CONTROL SWING...

Страница 702: ...8 CLUTCH SWITCH 120 OHM RED EPDM 2 0AWG MS999 1 A B C MS999 2 A B C MS999 3 A B C SHLD SHIELD J1939 CABLE 20 SHLD SHIELD J1939 CABLE 20 SHLD SHIELD J1939 CABLE 20 MS1000 1 A B C MS1000 2 A B C MS1000...

Страница 703: ...A B C SHLD SHIELD J1939 CABLE 20 SHLD SHIELD J1939 CABLE 20 SHLD SHIELD J1939 CABLE 20 SHLD SHIELD J1939 CABLE 20 MS1000 2 A B C MS1000 3 A B C MS1001 2 A B C MS1001 3 A B C MS1002 1 A B C MS1002 2 A...

Страница 704: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 112 3121619 Figure 7 116 Electrical Schematic Sheet 16 of 21...

Страница 705: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 113 Figure 7 117 Electrical Schematic Sheet 17 of 21...

Страница 706: ...R RTN 1 5mm WHT 44 38 INJCTR 1 5mm WHT 23 61 INJCTR RTN 1 5mm WHT 87 42 INJCTR 1 5mm WHT 66 37 INJCTR RTN 1 5mm WHT 25 20 MPROP 1 5mm WHT 46 19 MPROP RTN 1 5mm BLK 99 13 CAM ENG SPD WHT 100 14 CAM ENG...

Страница 707: ...RY ISOLATOR IGNITION START REQUEST CAN HIGH CHANNEL 2 CAN LOW CHANNEL 2 ALTERNATOR EXCITE CAN SHIELD EMR4 IGNITION GROUND GENERATOR ENABLE GLOW GENERATOR POWER GENERATOR GROUND PLUGGED PLUGGED GLOW PL...

Страница 708: ...TER UREA QUALITY LEVEL AND TEMP N6 CONNECTION UREA PURGE VALVE UREA PUMP SUPPLY MODULE HEATER UREA PRESSURE AFTER PUMP ENGINE HARNESS SHEET 10 ZONE A 2 3 ENGINE HARNESS SHEET 10 ZONE A 4 5 UREA TANK S...

Страница 709: ...ITION BLK GROUND BLK GROUND RED BATTERY RED BATTERY RED CAN HIGH RED CAN HIGH BLK CAN LOW BLK CAN LOW WHT CAN SHIELD WHT CAN SHIELD WHT IGNITION BLK GROUND WHT CAN SHIELD WHT CAN SHIELD BLK CAN LOW BL...

Страница 710: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 118 3121619 NOTES...

Страница 711: ......

Страница 712: ...rporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA 717 485 5161 Corporate 877 554 5438 Customer Support 717 485 6417 Visit our website for JLG Worldwide Locations www jlg c...

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